MECHENG 743: Composite Materials 1

Failure Analysis of
Composite Materials
Dr Tom Allen
Tom.allen@Auckland.ac.nz
MECHENG 743: Composite Materials 2
 MECHENG 743: Composite Materials 3

Failures happen!
How do we predict, pre-empt and prevent it?
 MECHENG 743: Composite Materials 4

What is structural failure?

• Breaks into multiple pieces

• Plastically deforms

• Loss of load-carry capacity

 MECHENG 743: Composite Materials 5

Lecture Structure

Increasing
Micromechanics geometric scale

Failure modes

Lamina Failure

Laminate failure

Progressive failure
 MECHENG 743: Composite Materials 6

Failure 2:
Micromechanics + Failure modes
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Recap: Constituent Materials

Reinforcement

Interface

Matrix

Micromechanics Failure modes Lamina failure Laminate failure Progressive failure

 MECHENG 743: Composite Materials 8

Failure of Constituent Materials

σ1 σ1
τ12 τ12

σ2 σ2 σ2 σ2

τ12 τ12
σ1 σ1

Micromechanics Failure modes Lamina failure Laminate failure Progressive failure

 MECHENG 743: Composite Materials 9

Failure of Constituent Materials

σ1
τ12

σ2 σ2

τ12
σ1

Homogeneous constituent materials can be analysed

independently i.e. von Mises criteria
1 1 1 1 2 
2 
( x   y )  ( y   z )  ( z   x )  3 yz  3 xz  3 xy   1
2 2 2 2 2

 s 2 2 2 

Micromechanics Failure modes Lamina failure Laminate failure Progressive failure

 MECHENG 743: Composite Materials 10

Failure of Composites: Rule of mixtures?

Does rule-of mixture apply?

ˆ  ˆ f v f  ˆ m vm
 
fibres
^f fibres

f1
matrix
m1 ^m matrix
 

^
^

ˆ  E f ˆv f  Emˆvm
Micromechanics Failure modes Lamina failure Laminate failure Progressive failure
 MECHENG 743: Composite Materials 11

Many failure modes

Tension

1. 4.
2.

5.
3.

Micromechanics Failure modes Lamina failure Laminate failure Progressive failure

 MECHENG 743: Composite Materials 12

Many failure modes

Compression

Micromechanics Failure modes Lamina failure Laminate failure Progressive failure

 MECHENG 743: Composite Materials 13

Compression Failure
A matrix dominated property!


N

ˆ G12
0  
ˆ   0 1   0 / ˆ
0

Micromechanics Failure modes Lamina failure Laminate failure Progressive failure

 MECHENG 743: Composite Materials 14

Compression Failure - Microbuckling

Micromechanics Failure modes Lamina failure Laminate failure Progressive failure

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Interlaminar

Micromechanics Failure modes Lamina failure Laminate failure Progressive failure

 MECHENG 743: Composite Materials 16

In-plane Failure Strength of Laminae

Strength Parameter Possible Failure Modes

Longitudinal Tension Fibre tensile failure
Fibre pullout
Longitudinal Compression Fibre compressive failure
Fibre microbuckling
Transverse Tension Matrix tensile failure
Fibre/matrix de-bonding
Fibre cleavage
Transverse Compression Matrix compressive failure
Matrix and interface shear failure
Shear Matrix shear failure
Interface shear failure
Micromechanics Failure modes Lamina failure Laminate failure Progressive failure
 MECHENG 743: Composite Materials 17

Failure 3:
Lamina failure
 MECHENG 743: Composite Materials 18

In-plane Failure Strength of Laminae

ˆ1t - Longitudinal Tensile Strength

ˆ1c - Longitudinal Compressive Strength
ˆ 2t - Transverse Tensile Strength

^

ˆ 2 c
2t

- Transverse Compressive Strength

^12
ˆ12 - Shear Strength 
^
1c

Similar for strain to failure 

^
1t

ˆ1t , ˆ1c , ˆ2t , ˆ2c , ˆ12 

^
2c

Micromechanics Failure modes Lamina failure Laminate failure Progressive failure

 MECHENG 743: Composite Materials 19

Lamina Data

Lamina 1 2 3 4 5 6 7
Fibre E-glass Boron Carbon Carbon Kevlar Carbon Carbon
(HT) (IM) 49 (HM)
Thickness 0.127 0.220 0.129 0.129 0.132 0.127 0.127
E1 [GPa] 40 210 136 151 75 147 181
E2 [GPa] 10 20 10 9.4 6 9 10.3
G12 [GPa] 5 6 5.2 4.8 2 3.3 7.17
n12 0.25 0.3 0.3 0.31 0.34 0.31 0.28
1t [MPa] 1100 1400 1800 2260 1400 2260 1500
1c [MPa] 600 2800 1200 1200 280 1200 1500
2t [MPa] 20 80 40 50 30 50 40
2c [MPa] 140 280 220 190 140 190 246
12 [MPa] 70 120 80 100 60 100 68
1t 0.028 0.007 0.013 0.015 0.019 0.015 0.0083
1c 0.015 0.013 0.009 0.008 0.004 0.008 0.0083
2t 0.002 0.004 0.004 0.005 0.005 0.005 0.0039
2c 0.014 0.014 0.021 0.020 0.023 0.021 0.0239
12 0.014 0.020 0.015 0.022 0.030 0.030 0.0095

Micromechanics Failure modes Lamina failure Laminate failure Progressive failure

 MECHENG 743: Composite Materials 20

Maximum Stress Criterion

 ˆ1c   1  ˆ1ct
 ˆ 2 c   2  ˆ 2 ct
ˆ12   12

1c
^ 
^


2t ^
1t

2c
^

Micromechanics Failure modes Lamina failure Laminate failure Progressive failure

 MECHENG 743: Composite Materials 21

Maximum Strain Criterion

ˆ1c  1  ˆ1ct
ˆ2 c   2  ˆ2 ct
^ 2t
ˆ12   12 
^
1c

^ 1t


^
2c

Micromechanics Failure modes Lamina failure Laminate failure Progressive failure

 MECHENG 743: Composite Materials 22

Tsai-Hill Criterion
von Mises

1 1 1 1 2 
2 
(   ) 2
 (   ) 2
 (   ) 2
 3 2
 3 2
 3 xy   1
 s 2
x y y z z x yz xz
2 2 

Hill

H ( 1   2 ) 2  F ( 2   3 ) 2  G( 3   1 ) 2  L 23
2
 M 132  N 122  1

G  H  12  F  H  22  F  G  32  2H 1 2 
2G 1 3  2 F 2 3  L 232  M 132  N 122  1

Micromechanics Failure modes Lamina failure Laminate failure Progressive failure

 MECHENG 743: Composite Materials 23

Tsai-Hill Criterion

• Perform (hypothetical) tests

1
• If only 12 acts: N 2
ˆ12
1
• If only 1 acts: GH  2
 1
• If only 2 acts: 1
FH 2
 2
• If only 3 acts: 1
FG 2
 3

Micromechanics Failure modes Lamina failure Laminate failure Progressive failure

 MECHENG 743: Composite Materials 24

Tsai-Hill Criterion
• Transversely isotropic lamina and plane stress gives

 2
 1 2   2 2
 2 
1
 2 12
1
 2
1  1   2
2
2
12

1c
^ 
^
2t 
^
1t


^
2c

Micromechanics Failure modes Lamina failure Laminate failure Progressive failure

 MECHENG 743: Composite Materials 25

Tsai-Wu Criterion
• Quadratic tensor criterion

Fij  i  j  Fi  i  1

 12  22  122 1 1  2  2
  2  2 F12 1 2     1
ˆ 1t ˆ 1c ˆ 2t ˆ 2c ˆ12 ˆ 1t ˆ 1c ˆ 2t ˆ 2 c


^


^


^

^

Micromechanics Failure modes Lamina failure Laminate failure Progressive failure

 MECHENG 743: Composite Materials 26

Failure 4:
Lamina safety factors
 MECHENG 743: Composite Materials 27

Tsai-Hill Criterion
• Transversely isotropic lamina and plane stress gives

 2
 1 2   2 2
 2 
1
 2 12
1
 2
1  1   2
2
2
12

1c
^ 
^
2t 
^
1t


^
2c

Micromechanics Failure modes Lamina failure Laminate failure Progressive failure

 MECHENG 743: Composite Materials 28

Tsai-Hill Criterion Safety factor

σ1
τ12

σ2 σ2 𝜎1 2 𝜎1 𝜎2 𝜎2 2 𝜏12 2
2 − 2 + 2 + 2 =C
𝜎1 𝜎1 𝜎2 𝜏12
τ12
σ1

𝑘𝜎1 2 (𝑘𝜎1 )(𝑘𝜎2 ) 𝑘𝜎2 2 (𝑘𝜏12 )2

− + + =1
𝜎12 𝜎12
𝜎22 2
𝜏12
Where k is your safety factor
Micromechanics Failure modes Lamina failure Laminate failure Progressive failure
 MECHENG 743: Composite Materials 29

Tsai-Hill Criterion Safety factor

𝜎1 2 𝜎1 𝜎2 𝜎2 2 𝜏12 2
𝑘2 2 − 2 + 2 + 2 =1
𝜎1 𝜎1 𝜎2 𝜏12

1
𝑘=
𝐶

Micromechanics Failure modes Lamina failure Laminate failure Progressive failure

 MECHENG 743: Composite Materials 30

Tsai-Wu Criterion Safety factor

𝜎1 2 𝜎2 2 𝜏12 2 𝜎1 𝜎1 𝜎2 𝜎2
+ + 2 + 2𝐹12 𝜎1 𝜎2 + − + − =C
𝜎1𝑡 𝜎1𝑐 𝜎2𝑡 𝜎2𝑐 𝜏12 𝜎1𝑡 𝜎1𝑐 𝜎2𝑡 𝜎2𝑐

(𝑘𝜎1 )2 (𝑘𝜎2 )2 (𝑘𝜏12 )2 𝑘𝜎1 𝑘𝜎1 𝑘𝜎2 𝑘𝜎2

+ + 2 + 2𝐹12 (𝑘𝜎1 )(𝑘𝜎2 ) + − + − =1
𝜎1𝑡 𝜎1𝑐 𝜎2𝑡 𝜎2𝑐 𝜏12 𝜎1𝑡 𝜎1𝑐 𝜎2𝑡 𝜎2𝑐
Where k is your safety factor

𝜎1 2 𝜎2 2 𝜏12 2 𝜎1 𝜎1 𝜎2 𝜎2
𝑘2 + + 2 + 2𝐹12 𝜎1 𝜎2 + 𝑘 − + − =1
𝜎1𝑡 𝜎1𝑐 𝜎2𝑡 𝜎2𝑐 𝜏12 𝜎1𝑡 𝜎1𝑐 𝜎2𝑡 𝜎2𝑐

Solve for k….

Micromechanics Failure modes Lamina failure Laminate failure Progressive failure

 MECHENG 743: Composite Materials 31

Tsai-Wu Criterion Safety factor

2
𝜎 𝜎 𝜎 𝜎 𝜎1 𝜎 𝜎 𝜎 𝜎1 2 𝜎2 𝜏 2
− 1 − 1 + 2 − 2 ± − 1 + 2 − 2 +4 + 2 + 12 2 + 2𝐹12 𝜎1 𝜎2
𝜎1𝑡 𝜎1𝑐 𝜎2𝑡 𝜎2𝑐 𝜎1𝑡 𝜎1𝑐 𝜎2𝑡 𝜎2𝑐 𝜎1𝑡 𝜎1𝑐 𝜎2𝑡 𝜎2𝑐 𝜏12
𝑘=
𝜎1 2 𝜎2 𝜏 2
2 + 2 + 12 2 + 2𝐹12 𝜎1 𝜎2
𝜎1𝑡 𝜎1𝑐 𝜎2𝑡 𝜎2𝑐 𝜏12

Micromechanics Failure modes Lamina failure Laminate failure Progressive failure

 MECHENG 743: Composite Materials 32

Failure 5:
Laminate/ progressive failure
 MECHENG 743: Composite Materials 33

Progressive Failure Analysis

Input:
Laminate details
Material properties
LPF Load case
Stress
Calculate Laminate Stiffness Matrix
FPF A, B, D

Apply increment of load, calculate

laminate strains and curvatures

Calculate lamina strains and stresses

Evaluate failure criterion

Reduce stiffness of failed lamina

Strain
Have all lamina failed?
No Yes
End: LFP reached

Micromechanics Failure modes Lamina failure Laminate failure Progressive failure

 MECHENG 743: Composite Materials 34

Progressive Failure Analysis in FEM

Material State Elastic Properties

No failure E1 E2 n12 G12
Matrix failure E1 0 0 G12
Fibre failure (tension) 0 E2 n12 G12
Fibre/matrix shear E1 E2 0 0
Shear failure E1 E2 n12 0
Matrix failure + fibre/matrix shear E1 0 0 0
Matrix failure + shear damage E1 0 0 0
Fibre/matrix shear + shear damage E1 E2 0 0
All failure modes 0 0 0 0

Micromechanics Failure modes Lamina failure Laminate failure Progressive failure