Mall, S. | Engineering Papers

NASA NTRS1989

Effect of bond thickness on fracture and fatigue strength of adhesively bonded composite joints

An experimental investigation of composite to composite bonded joints was undertaken to study the effect of bond thickness on debond growth rate under cyclic loading and critical strain energy release rate under static loading. Double cantilever beam specimens of graphite/epoxy adherends bonded with EC 3445 were tested under mode I loading. A different behavior of fracture and fatigue strength was observed with variation of bondline thickness.

Mall, S.↗

NASA NTRS1988

Debonding characteristics of adhesively bonded woven Kevlar composites

The fatigue damage mechanism of an adhesively bonded joint between fabric reinforced composite adherends was investigated with cracked-lap-shear specimens. Two bonded systems were studied: fabric Kevlar 49/5208 epoxy adherends bonded together with either EC 3445 or FM-300 adhesive. For each bonded system, two specimen geometries were tested. In all specimens tested, fatigue damage occurred in the form of cyclic debonding; however, the woven Kevlar specimens gave significantly slower debond growth rates and higher fracture toughness than previously found in the nonwoven adherend specimens. The surfaces for the woven adherends were not smooth; rather, they had regular crests (high spots) and troughs (low spots) due to the weave pattern. Radiographs of the specimens and examination of their failure surfaces revealed that fiber bridging occurred between the crests of the two adherends in the debonded region. The observed improvements in debond growth resistance and static fracture toughness are attributed to this bridging.

Mall, S.↗

NASA NTRS1988

Characterization of debond growth mechanism in adhesively bonded composites under mode II static and fatigue loadings

An experimental investigation of adhesively bonded composite joint was conducted to characterize the debond growth mechanism under mode II static and fatigue loadings. For this purpose, end-notched flexure specimens of graphite/epoxy (T300/5208) adherends bonded with EC 3445 adhesive were tested. In all specimen tested, the fatigue failure occurred in the form of cyclic debonding. The present study confirmed the result of previous studies that total strain-energy-release rate is the driving parameter for cyclic debonding. Further, the debond growth resistance under cyclic loading with full shear reversal (i.e., stress ratio, R = -1) is drastically reduced in comparison to the case when subjected to cyclic shear loading with no shear reversal (i.e., R = 0.1).

Mall, S.↗

NASA NTRS1987

Stress ratio effect on cyclic debonding in adhesively bonded composite joints

A study was conducted to investigate the stress ratio effect on cyclic debond growth behavior in adhesively bonded composite joints. The system studied consisted of graphite/epoxy adherends bonded with a toughened epoxy adhesive. This study showed that the strain energy release rate range was the driving factor for cyclic debonding of the tested bonded system when subjected to cyclic loads with different stress ratios for both mode I and mixed mode I-II loadings.

Mall, S.↗

NASA NTRS1986

Criterion for mixed mode fracture in composite bonded joints

A study was undertaken to characterize the debond growth mechanism of adhesively bonded composite joints under mode I, mixed mode I-II, and mode II static loadings. The bonded system consisted of graphite-epoxy composite adherends bonded with a toughened epoxy adhesive. The mode I, mode II and mixed mode I-II fracture energies of the tested adhesives were found to be equal to each other. The criterion for mixed mode fracture in composite bonded joints was found.

Mall, S.↗

NASA NTRS1986

Finite element analysis of end notch flexure specimen

A finite element analysis of the end notch flexure specimen for mode II interlaminar fracture toughness measurement was conducted. The effect of friction between the crack faces and large deflection on the evaluation of G sub IIc from this specimen were investigated. Results of this study are presented in this paper.

Mall, S.↗

NASA NTRS1986

Influence of interface ply orientation on fatigue damage of adhesively bonded composite joints

An experimental study of cracked-lap-shear specimens was conducted to determine the influence of adherend stacking sequence on debond initiation and damage growth in a composite-to-composite bonded joint. Specimens consisted of quasi-isotropic graphite/epoxy adherends bonded together with either FM-300 or EC 3445 adhesives. The stacking sequence of the adherends was varied such that 0 deg, 45 deg, or 90 deg plies were present at the adherend-adhesive interfaces. Fatigue damage initiated in the adhesive layer in those specimens with 0 deg and 45 deg interface plies. Damaage initiated in the form of ply cracking in the strap adherend for the specimens with 90 deg interface plies. The fatigue-damage growth was in the form of delamination within the composite adherends for specimens with the 90 deg and 45 deg plies next to the adhesive, while debonding in the adhesive resulted for the specimens with 0 deg plies next to the adhesive. Those joints with the 0 deg and 45 deg plies next to either adhesive has essentially the same fatigue-damage-initiation stress levels. These stress levels were 13 and 71 percent higher, respectively, than those for specimens with 90 deg plies next to the EC 3445 and FM-300 adhesives.

Johnson, W. S.↗

NASA NTRS1986

Characterization of mode I and mixed-mode failure of adhesive bonds between composite adherends

A combined experimental and analytical investigation of an adhesively bonded composite joint was conducted to characterize both the static and fatigue beyond growth mechanism under mode 1 and mixed-mode 1 and 2 loadings. Two bonded systems were studied: graphite/epoxy adherends bonded with EC 3445 and FM-300 adhesives. For each bonded system, two specimen types were tested: a double-cantilever-beam specimen for mode 1 loading and a cracked-lapshear specimen for mixed-mode 1 and 2 loading. In all specimens tested, failure occurred in the form of debond growth. Debonding always occurred in a cohesive manner with EC 3445 adhesive. The FM-300 adhesive debonded in a cohesive manner under mixed-mode 1 and 2 loading, but in a cohesive, adhesive, or combined cohesive and adhesive manner under mode 1 loading. Total strain-energy release rate appeared to be the driving parameter for debond growth under static and fatigue loadings.

Mall, S.↗

NASA NTRS1986

Finite-element analysis of end-notch flexure specimens

A finite-element analysis of the end-notch flexure specimen for Mode II interlaminar fracture toughness measurement was conducted. The effects of friction between the crack faces and large deflection on the evaluation of G(IIc) from this specimen were investigated. Results of this study are presented in this paper.

Mall, S.↗

NASA NTRS1986

Loading rate effect on interlaminar fracture toughness of a thermoplastic composite

A study was undertaken to investigate the loading rate effect on delamination fracture initiation toughness of a thermoplastic composite. For this purpose, double cantilever beam specimens of graphite/PEEK were tested in a displacement controlled mode using an Instron tensile test machine. Specimens were loaded at various crosshead speeds ranging from 0.05 cm/min to 100 cm/min. The interlaminar fracture toughness was found to decrease with increasing loading rate, and this decrease was more than one hundred percent over the five decades of loading rate employed.

Mall, S.↗

NASA NTRS1986

Crack-surface displacements for two symmetric cracks emanating from a circular hole in an infinite plate

An analytical model is presented for the surface displacement associated with two symmetric cracks radiating from a circular hole in a plate undergoing remote uniform stress. The model equations account for the stress intensity factor (Kic), the boundary conditions enveloping the hole, and the effects of symmetric forces concentrated around the hole. The displacement(s) of the surface are calculated at a given distance from the hole along the crack(s).

Mall, S.↗

NASA NTRS1986

Criterion for mixed mode fracture in composite bonded joints

A study was undertaken to characterize the debond growth mechanism of adhesively bonded composite joints under mode I, mixed mode I-II, and mode II static loadings. The bonded system consisted of graphite/epoxy (T300/5208) composite adherends bonded with a toughened epoxy (EC 3445) adhesive. The mode I, mode II and mixed-mode I-II fracture energies of the tested adhesive were found to be equal to each other. Furthermore, the criterion for mixed mode fracture in composite bonded joints was determined.

Mall, S.↗

NASA NTRS1985

Interaction of mixed mode loading on cyclic debonding in adhesively bonded composite joints

A combined experimental and analytical investigation of an adhesively-bonded composite joint was conducted to characterize the fracture mode dependence of cyclic debonding. The system studied consisted of graphite/epoxy adherends bonded with EC 3445 adhesive. Several types of specimens are tested which provide the cyclic debond growth rate measurements under various load conditions: mode 1, mixed mode 1 to 2, and mostly mode 2. This study shows that the total strain-energy-release rate is the governing factor for cyclic debonding.

Mall, S.↗

NASA NTRS1985

Interaction of mixed mode loading on cyclic debonding in adhesively bonded composite joints

A combined experimental and analytical investigation of an adhesively-bonded composite joint was conducted to characterize the fracture mode dependence of cyclic debonding. The system studied consisted of graphite/epoxy adherends bonded with EC 3445 adhesive. Several types of specimens are tested which provide the cyclic debond growth rate measurements under various load conditions: mode 1, mixed mode 1 to 2, and mostly mode 2. This study shows that the total strain-energy-release rate is the governing factor for cyclic debonding.

Mall, S.↗

NASA NTRS1985

Mixed-mode cyclic debonding of adhesively bonded composite joints

A combined experimental-analytical investigation to characterize the cyclic failure mechanism of a simple composite-to-composite bonded joint is conducted. The cracked lap shear (CLS) specimens of graphite/epoxy adherend bonded with EC-3445 adhesive are tested under combined mode 1 and 2 loading. In all specimens tested, fatigue failure occurs in the form of cyclic debonding. The cyclic debond growth rates are measured. The finite element analysis is employed to compute the mode 1, mode 2, and total strain energy release rates (i.e., GI, GII, and GT). A wide range of mixed-mode loading, i.e., GI/GII ranging from 0.03 to 0.38, is obtained. The total strain energy release rate, G sub T, appeared to be the driving parameter for cyclic debonding in the tested composite bonded system.

Rezaizadeh, M. A.↗

NASA NTRS1985

Influence of interface ply orientation on fatigue damage of adhesively bonded composite joints

An experimental study of cracked-lap-shear specimens was conducted to determine the influence of adherend stacking sequence on debond initiation and damage growth in a composite-to-composite bonded joint. Specimens consisted of quasi-isotropic graphite/epoxy adherends bonded together with either FM-300 or EC 3445 adhesives. The stacking sequence of the adherends was varied such that 0 deg, 45 deg, or 90 deg plies were present at the adherend-adhesive interfaces. Fatigue damage initiated in the adhesive layer in those specimens with 0 deg nd 45 deg interface plies. Damage initiated in the form of ply cracking in the strap adherend for the specimens with 90 deg interface plies. The fatigue-damage growth was in the form of delamination within the composite adherends for specimens with the 90 deg and 45 deg plies next to the adhesive, while debonding in the adhesive resulted for the specimens with 0 deg plies next to the adhesive. Those joints with the 0 deg and 45 deg plies next to either adhesive has essentially the same fatigue-damage-initiation stress levels. These stress levels were 13 and 71 percent higher, respectively, than those for specimens with 90 deg plies next to the EC 3445 and FM-300 adhesives.

Johnson, W. S.↗

NASA NTRS1985

Characterization of mode 1 and mixed-mode failure of adhesive bonds between composite adherends

A combined experimental and analytical investigation of an adhesively bonded composite joint was conducted to characterize both the static and fatigue beyond growth mechanism under mode 1 and mixed-mode 1 and 2 loadings. Two bonded systems were studied: graphite/epoxy adherends bonded with EC 3445 and FM-300 adhesives. For each bonded system, two specimen types were tested: a double-cantilever-beam specimen for mode 1 loading and a cracked-lapshear specimen for mixed-mode 1 and 2 loading. In all specimens tested, failure occurred in the form of debond growth. Debonding always occurred in a cohesive manner with EC 3445 adhesive. The FM-300 adhesive debonded in a cohesive manner under mixed-mode 1 and 2 loading, but in a cohesive, adhesive, or combined cohesive and adhesive manner under mode 1 loading. Total strain-energy release rate appeared to be the driving parameter for debond growth under static and fatigue loadings.

Mall, S.↗

NASA NTRS1985

A fracture mechanics approach for designing adhesively bonded joints

An analytical and experimental investigation was undertaken to determine if the adhesive debond initiation stress could be predicted for arbitrary joint geometries. The analysis was based upon a threshold total strain-energy-release rate (Gth) concept. Two bonded systems were tested: T300/5208 graphite/epoxy adherends bonded with either EC-3445 or FM-300 adhesive. The Gth for each adhesive was determined from cracked-lap-shear (CLS) specimens by initiation tests. Finite-element analyses of various tapered CLS specimen geometries predicted the specimen stress at which the total strain-energy-release rate (GT) equaled Gth at the joint tip. Experiments verified the predictions. The approach described herein predicts the maximum stress at which an adhesive joint can be cycled yet not debond. Furthermore, total strain-energy-release rate appeared to be the driving parameter for cyclic debonding and debond initiation in structural adhesives. In addition, debond initiation and growth were found to occur with virtually no peel stress present.

Johnson, W. S.↗