Weft direction tension-tension fatigue responses of layer-to-layer 3D angle-interlock woven composites at room and elevated temperatures
Introduction
Conventional laminated composites deliver the reliant in-plane stiffness, however, do not offer good through-thickness properties. 3D layer-to-layer angle-interlock resin matrix woven composites, commonly named by 2.5D woven composites (2.5DWC), have been developed as a novel category of new lightweight 3D woven composites [1]. Compared to 2D laminated or 2D woven composites (2DWC), the 2.5DWC possess many advantages, i.e. higher out-of-plane properties, better structural integrity and superior fatigue resistance [2], [3]. However, it is well known that the promising use of 2.5DWC in new applications, i.e. blades and cases of the aeroengine, where the structure may experience fatigue loading at non-ambient temperatures. Thus, it is of vital importance to understand the temperature-dependent fatigue behaviors of 2.5DWC in order to be further applied in the field of aeroengine.
Static mechanical behaviors of resin matrix woven composites have been investigated at room and elevated temperatures based on experimental and numerical approaches [4], [5]. Zhang et al. [6] investigated the warp direction static mechanical behaviors of 2.5DWC at room temperature (RT), and a meso-scale voxel-based model was developed. Zheng et al. [7] proposed a weft direction yield criterion of 2.5DWC based on the experimental phenomenon, and found that transversal crack of resin was the reason for yielding nonlinearity under the weft direction static loading. Lu et al. [8] developed a two-step, multi-scale progressive damage analysis approach to predict the on-/ off-axis stress-strain behaviors of 2.5DWC. Over the last decade, due to the development of innovative high-temperature resin and manufacturing technology, the thermo-mechanical behaviors of resin matrix woven composites have been significantly focused. Wang et al. [9] experimentally investigated the effects of temperature and strain rate on the mechanical properties and fracture mechanism of 2DWC over a range of temperature (218–448 K). Fang et al. [10] assessed the temperature-dependent compressive response of 2DWC at 25 °C, 95 °C and 125 °C, and found that a transition failure mode from broom to kink band with the rise of temperature. In our previous work [11], the warp/ weft direction thermo-mechanical behaviors of 2.5DWC at 20 °C and 180 °C, were experimentally and numerically studied. Results showed that although the temperature facilitated the softening of resin matrix and stress concentration, the load-carrying fiber yarns still determined the damage propagation behaviors and fiber-dominated failure modes were observed.
Apart from static mechanical behaviors, temperature-dependent fatigue behaviors of resin matrix woven composites are increasingly being attended [12], [13]. Montesano et al. [14] studied the fatigue behaviors of 2DWC at RT and 225 °C based on experiment. The results demonstrated that the initial stiffness degradation was more obvious at 225 °C than that at RT, which could be attributed that substantial resin matrix failure emerged at an earlier stage at 225 °C. Selezneva et al. [15] experimentally evaluated the fatigue failure mechanism of 2DWC at 205 °C. The results showed that load-carrying fiber yarns would be prone to rotate toward to loading direction at 205 °C, due to the premature failure of resin matrix. Wilkinson et al. [16] evaluated the fatigue behavior of 3DWC and 2DWC at RT and 329 °C, and found that due to the microstructural defects induced by inserting Z-fibers (Incorporating through-thickness reinforced yarns), the 2DWC provides better fatigue property at RT than the 3DWC at 329 °C, but Z-fibers can significantly improve the delamination-resistant capacity of 3DWC. Vieille et al. [17] investigated the fatigue damage accumulation of thermoset 2DWC at high temperature, and results showed that the matrix ductility was prominent to determine the high-temperature fatigue behavior of 2DWC. Rajaneesh et al. [18] proposed an accelerated testing methodology to investigate the flexural fatigue behavior of 2DWC at different temperatures among 50 °C to 100 °C. Wang et al. [19] evaluated the influence of temperature on the dynamic behavior of woven composites at RT, 95 °C and 125 °C based on macro- and microscopic observation and C-scan inspections. To reveal the temperature-dependent fatigue damage mechanisms of 2DWC, Foti et al. [20] recorded the real-time damage processes at RT and 250 °C using μ-Computed Tomography and Digital Image Correlation.
In addition to experimental investigation, a few fatigue life prediction models of composites were developed, but the majority of them were established in room temperature case. Rafiee et al. [21] successfully predicted the room temperature fatigue life of laminated composite pipes based on a progressive damage modeling (PDM) technique, where the technique consists of three phases as stress analysis, damage evaluation and stiffness degradation. Additionally, a stochastic fatigue life prediction model based on PDM technique was follow-up proposed by Rafiee, and the room temperature fatigue life of a laminated composite ring was experimentally and numerically investigated.[22], [23]. Khan et al. [24] proposed a temperature-dependent fatigue life prediction model for 2DWC, where the temperature was incorporated into the damage variables. Koumpias et al. [25] proposed a temperature dependence of fatigue life prediction model of 3DWC using a homogenized approach. Although the temperature-dependent fatigue behaviors of woven composites have a certain research foundation, the investigation regarding to fatigue behaviors of 2.5DWC is considerably limited. Qiu et al. [26] experimentally investigated the room temperature fatigue behaviors of 2.5DWC, and found that the warp and weft direction fatigue behaviors were obviously different. Based on the progressive damage theory, a room temperature fatigue life prediction model for 2.5DWC was proposed. In our previous research [27], the warp direction fatigue behaviors of 2.5DWC at RT and 180 °C were studied, and based on Mao’s damage model [28], and the warp direction residual stiffness vs. fatigue life curves of 2.5DWC at various temperatures were predicted. However, due to the anisotropic characteristic, weft direction fatigue behaviors of 2.5DWC at different temperatures are merely focused.
In this work, T300/QY8911-IV 2.5D woven composites were firstly fabricated by Resin Transfer Molding (RTM). Afterwards, the weft direction fatigue behaviors of 2.5DWC were explored at RT and 180 °C using experimental and numerical methods. To be more specific, (**1) Temperature dependence of weft direction fatigue life and residual strength were experimentally elaborated; (**2) A probable weft direction fatigue damage mechanism was proposed; (**3) Fatigue properties, such as weft direction fatigue life, damage propagation process, residual stiffnesses and fracture morphology of 2.5DWC at RT and 180 °C were simulated.
Section snippets
Materials
T300 carbon fiber yarn (3 K filaments per bundle) was adopted as the reinforcement and high-temperature thermosetting resin (QY8911-IV, glass transition temperature: 256 °C) was used as matrix. The mechanical properties of T300 carbon fiber and QY8911-IV resin at various temperatures were listed in Table 1. A 3D layer-to-layer angle-interlock woven fabric, viz. 2.5D woven fabric, was firstly weaved in Tiangong University, which consists of six ply weft and seven ply warp. There are two main
Fatigue progressive damage model considering the effect of temperature
Nowadays, the damage behavior of woven composites during the fatigue loading process can be predicted based on fatigue progressive damage model (PDM) [34], comprising that fatigue failure criteria and material property degradation law. In this work, the effect of temperature on the fatigue responses of 2.5DWC was incorporated into the fatigue progressive damge model. In addition, the transverse isotropy with “1-2-3” local coordinate system was adopted for warp and weft yarns, whereas the
Weft direction static tests at room and elevated temperatures
Three static tests were performed at room temperature (~20 °C), while additional three static tests were conducted at elevated temperature (180 °C). Fig. 4 illustrates all the stress vs. strain curves, and the test results are given in Table 4.
In Fig. 4, all the room temperature curves present a bilinear behavior up to the ultimate breakage, whereas all the elevated temperature curves totally exhibit a slight nonlinear response at the end stage. As discussed in our previous work [11], since the
Conclusion
Weft direction fatigue behaviors of T300/ QY8911-IV 2.5D woven composites at room and elevated temperatures were unambiguously elaborated using experimental and numerical approaches. The test program obtained the weft direction fatigue lives, residual strengths and fracture morphologies at 20 °C and 180 °C. The simulation program obtained the temperature dependence of fatigue life prediction model and predicted the weft direction damage propagation processes, residual stiffnesses and failure
Declaration of Competing Interest
The authors declare that they have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this paper.
Acknowledgements
The support for this research has been provided by the National Natural Science Foundation of China (Grant No. 51905350, 51778373).
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