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05 CENG8432 Fracture Mechanics of Composites, Sandwich Construction
05 CENG8432 Fracture Mechanics of Composites, Sandwich Construction
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
Sandwich Construction
It is a type of stresses‐skin construction with the skins carrying the major applied
loads, in‐plane loads and flatwise bending moments.
The stiffness, stability, configuration and strength of the panel are determined by
the skins, stabilised by the core.
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
Sandwich Construction
In the literature [Allen 1969, Plantema 1966, Vinson 1999, Zenkert 1997]…
There is the analysis and design aspects of sandwich constructions, e.g. beams,
panels, shells.
A sandwich construction is shown in Fig. 1 and Fig. 2.
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
Sandwich Construction
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
Sandwich Construction
The sandwich construction is like an “I” cross‐section where the face sheets are
comparable with the flanges, carrying the tension and compression forces, and
the core of sandwich construction is comparable with a web, carrying the shear
forces.
Most times a honeycomb core, made of Al‐alloy, is used as a core in sandwich
construction applied for spacecraft and launch vehicles.
More information about the mechanics of honeycombs can be easily find in
somewhere of internet.
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
Sandwich Construction
The major design aspects of sandwich constructions are:
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
Sandwich Construction
• The core shall have good compression properties to prevent crushing of the core.
The crushing property is one of the design parameters to estimate the wrinkling
of the face sheet.
• The diameter of the cells (in case of honeycomb core) shall be selected to
prevent intercell buckling of the unsupported face sheet.
• The sandwich construction shall have good overall stiffness properties.
• The adhesive between the face sheets and the core shall have good strength
properties
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
Sandwich Construction
<Optimum design>
: Determination of core and face sheet thickness for minimum mass
The optimum ratio between the core height (m) and face sheet thickness (m), can
be optimised with respect to a minimum mass (kg/m) of the sandwich
construction. The mass will be contributed by the mass of the face sheets (kg/m),
the mass of both face sheets (in this case equal face sheets) and the mass per unit
of area of both adhesive layers . The total mass per unit area becomes
During the optimisation the mass of the adhesive layers will be ignored.
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
Sandwich Construction
In the following Table 10.1 equations for the minimum mass optimisation are
given [Allen 1969].
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
Sandwich Construction
<Stresses>
The stresses will occur both in the face sheets and in the core.
The stress in the face sheets are caused by bending moments and in plane forces.
Non uniform in plane forces will lead to shear stresses. The face sheets are in
general very thin. That means that the stresses in the face sheets are more or less
membrane stresses and we assume no stress variations in the face sheets through
the thickness, when,
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
Sandwich Construction
<<Stresses in face sheets>>
Bending stresses
The bending stress σfb in the face sheets of a sandwich construction due to a
bending moment per unit of width (Nm/m) is illustrated in Fig. 10.4.
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
Sandwich Construction
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
Sandwich Construction
Tensile, compression stresses
In plane stress σfn is caused by the in plane internal load N per unit of width [N/m].
This is shown in Fig. 10.5. The in plane loads are carried by both face sheets. The
core will not carry the in plane loads. The in plane tensile or compression stress
can be calculated with
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
Sandwich Construction
Total stress in face sheets
The total stress σf in the face sheets in the superposition of the bending stress σfb
with the in plane stress σfn. The total stress σf becomes
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
Sandwich Construction
<< Shear stress >>
The maximum shear stress τ, caused by the shear force D per unit width (N/m),
can be calculated with the Jourawski method
where Sf is the first moment of area per unit width of the face sheet with
respect to the neutral line and I is the second moment of area per unit width of
the face sheet with respect to the neutral line.
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
Sandwich Construction
Failure modes
• Facing failure: Initial failure may occur in either compression or tension in the
face sheet caused by insufficient panel thickness, face sheet thickness or face
sheet strength.
• Transverse shear failure: Caused by insufficient core strength or panel thickness.
• Local crushing of core: Caused by low core compression strength.
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
Sandwich Construction
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
Sandwich Construction
Buckling Sandwich Columns
Let L denote the length of the column, F the axial compression force, the core
thickness hc and the shear modulus Gc, the face sheets have a thickness tf, a width
b and an axial elastic modulus Ef. The sandwich column is illustrated in Fig.
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
Sandwich Construction
The shear stiffness of the sandwich column GcA is given by
The Euler buckling of a pinned‐pinned column is
In the paper of Bazant [Bazant 2003], two expressions are given to calculate the
critical compression load for a sandwich column
Engesser published his equation in 1889 and Haringx published his equation in
1942.
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
Sandwich Construction
Global Buckling Cylinder
The compression stresses introduced into the faces of the sandwich cylinder
subjected to an axial compression load F, where
The compression stress σx,f in the both equal thickness face sheets with thickness
tf is given by
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
Sandwich Construction
Global Buckling Cylinder
The critical value Nx, cr of the running load per unit of circumference of a long
cylinder, simply supported, is [Vinson 1999]
where Ef is the Young’s modulus, νf is the Poisson’s ratio of the face sheet
material and Gc is the shear modulus of the core.
γ is the knock down factor related to initial imperfections and is given by,
[NASA SP‐8007]
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
Sandwich Construction
In case
is above the yield stress, the Young’s modulus Ef shall be corrected with a
plasticity factor η.
In [NASA SP‐8007] it is recommended to replace with , where
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
Sandwich Construction
Local Buckling
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
The design equations for the mentioned local buckling failures are given in Table
10.3.
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
Example
We have a sandwich plate with Al‐alloy face sheets and an Al‐alloy honeycomb core
1/4‐5056‐.0015p (Table 10.5) with • tf = 0.2 , hc = 20, dc = 6.4mm • Ef = 70 GPa
• Ec = 2.17 Mpa • GL = 345, GT = 152,
plasticity factor η
must be used to
correct (lower) the
dimpling stress.
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
Sandwich Construction
Combined Loads
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
Sandwich Construction
Inserts
Inserts are bonded in the sandwich construction core and used to introduce loads
in the sandwich construction. The insert is embedded in a potting material,
generally with a cylindrical shape. The potting shall be capable to transfer loads
from the insert into the core.
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
The pre‐stress in the bolts, due to prescribed torques, is taken by the winding of the
threads and is not transferred into the sandwich construction.
The quasi‐static loads are for boxes less critical than random loads caused by the
random vibrations.
The 3σ acceleration , caused by random vibrations, can be calculated with
Miles’ equation
with fn:the natural frequency of mode with significant effective mass of the
mechanical system (e.g. spacecraft), Q the amplification factor (in general,
where M is the mass (kg) of the box.
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
Honeycomb mechanical properties
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
Typical connections
Some examples (Typical sandwich edge connections) of sandwich construction
connection are illustrated in Fig.
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
Exercises : Stiffness Sandwich Beam
A sandwich beam is simply supported at both ends as illustrated in Fig. 10.11.
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
Metal Matrix Composites
Metal matrix composites (MMCs) comprise a relatively wide range of materials
defined by the metal matrix, reinforcement type, and reinforcement geometry.
In the area of the matrix, most metallic systems have been explored for use in
metal matrix composites, including Al, Be, Mg, Ti, Fe, Ni, Co, and Ag.
By far the largest usage is in aluminum matrix composites.
From a reinforcement perspective, the materials used are typically ceramics since
they provide a very desirable combination of stiffness, strength, and relatively low
density. Candidate reinforcement materials include SiC, Al2O3, B4C, TiC, TiB2,
graphite, and a number of other ceramics. In addition, there has been work on
metallic materials as reinforcements, notably W and steel fibers
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
Metal Matrix Composites
The morphology of the reinforcement material is another variable of importance in
metal matrix composites. The three major classes of reinforcement morphology
are continuous fiber, chopped fiber or whisker, and particulate. Typically selection
of the reinforcement morphology is determined by the desired property/cost
combination. Generally, continuous fiber reinforced MMCs provide the highest
properties in the direction of the fiber orientation but are the most expensive.
Chopped fiber and whisker reinforced materials can produce significant property
improvements in the plane or direction of their orientation, at somewhat lower
cost. Particulates provide a comparatively more moderate but isotropic increase in
properties and are typically available at the lowest cost.
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
Metal Matrix Composites
By adding to the three variables of metallic matrix, reinforcement material, and
reinforcement morphology, the further options of reinforcement volume fraction,
orientation, and matrix alloy composition and heat treatment, it is apparent that
there is a very wide range of available material combinations and resultant
properties.
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
Advantages of MMCs
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
Degrading properties in MMCs
Are there any properties
which degrade when
metals are reinforced
with fibers?
2a
Yes, they may have
reduced ductility and
fracture toughness.
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
Typical mechanical properties of metal matrix composites
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
REINFORCEMENTS
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
Carbon Fibers
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
Carbon Fibers
The steps common to all processes of carbon fiber manufacture are as follows:
(a) Fiberization, i.e., extrusion of a polymer melt or solution into a precursor fiber.
(b) Stabilization (oxidation or thermosetting) is done at relatively low temperatures
(200‐450°C), usually in air. This renders the precursor infusible during subsequent
high temperature processing.
(c) Carbonization is carried out in an inert atmosphere (pure N2 generally) at 1000‐
2000°C. At the end of this step the fiber has 85‐99% carbon content.
(d) Graphitization (optional) is done in Ar or N2 at a temperature greater than
2500°C. This step increases the carbon content to more than 99% and imparts a
very high degree of preferred orientation to the fiber.
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
Boron Fiber
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
Boron Fiber
Some important characteristics of any CVD process of making fibers are:
Unlike conventional fiber forming processes, the CVD fibers are not formed by
stretching or drawing, i.e., there is no lengthening; instead, lateral growth by
thickening occurs.
The final diameter of the fiber may be as much as 10 times that of the starting
fiber substrate.
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
Boron Fiber
Boron fiber made by deposition on a tungsten
substrate can result in complex reaction products at
the corelsheath interface. A boron fiber cross section
(100 pm diameter) is shown in Fig. 2.10(a) while Fig.
2.10(b) shows, schematically, the various subparts of
the cross‐section. Depending on the temperature
conditions during deposition, the W core may consist
of a series of compounds such as W, W2B, WB, W&,
and WB4. These tungsten boride phases form by
diffusion of B into W.
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
Boron Fiber
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
Schematic of
Diffusion Bonding
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
STRENGTHENING MECHANISMS
The monotonic strength and stiffness of MMCs is usually much higher than that
of the unreinforced metal. Figure shows a general schematic of the evolution of
damage in a MMC during monotonic loading.
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
STRENGTHENING MECHANISMS
This is shown schematically in Fig. 7.2. Let's assume a single high stiffness fiber
embedded in a lower modulus matrix.
The composite is loaded without direct
loading of the fiber itself. If a set of
parallel imaginary lines are drawn on
the composite, after loading the lines
will become distorted because of the
shear stresses generated by differing
axial displacements in fiber and matrix.
Thus, load transfer to the fiber occurs
by means of shear strains in the matrix.
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
STRENGTHENING MECHANISMS
Let us consider the case of a purely elastic fiber in an elastic matrix
mathematically, Fig. 7.3. Let u be displacement in the matrix in the presence of
the fiber, at a distance x from one end, and let v be the displacement at x in the
absence of the fiber. If Pf is the normal load on the fiber, then we can write the
following expression for load transfer from the matrix to the fiber:
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
STRENGTHENING MECHANISMS
The exact expression for B is described later in this section. Differentiating eq. 1,
we get:
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
Figure shows the variation of τ and σ with distance x. At the ends of the fiber,
the axial stress is zero. It increases until it reaches of, in the center of the fiber
(assuming a sufficiently long fiber that will enable the stress to build to of of σfu).
The shear stress is a maximum at the fiber ends, and a minimum in the center
of the fiber.
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
Ceramic Matrix Composites
What are ceramic matrix composites?
Advantages of CMCs
High strength, hardness and high service temperatures
Chemical inertness
Low Density
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
Table. Typical fracture toughness of monolithic materials
and ceramic matrix composites
SiC/A2O3 27 24.6
SiC/SiC 30 27.3
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
Table 1.13 Typical mechanical properties of some
ceramic matrix composites
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
Fibers
G lass Slurry Tan k
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
Carbon‐Carbon Composites
What are carbon‐carbon composites?
Carbon ‐ Carbon composites have carbon fibers in carbon matrix.
Advantages of Carbon‐Carbon Composites
Gradual failure
Withstand high temperatures
Low creep at high temperatures
Low density
High thermal conductivity
Low and tailorable coefficient of thermal expansion
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
Table 1.14 Typical mechanical properties of carbon‐carbon
matrix composites
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
Carbon‐Carbon Manufacturing
Step 1 Step 2
Step 4 Step 5
Standard Lay-up
Gr/Phenolic and Pyrolysis Coating Sealing
Prepreg Cure
After 3 Impregnations
Resin
Impregnation
Step 3
CENG 8432
Mechanics of
Composite
Fracture Mechanics of Composites, Sandwich
Materials Construction, Metal and Ceramic Matrix Composites
Applications of C‐C Composites
Space Shuttle Nose Cones
Re‐entry temperature of 3092 K
Aircraft Brakes
Saves 450 kgs of mass
2‐4 times durability vs. steel
2.5 times specific heat of steel