SAMPLE RESEARCH PROPOSAL (This proposal has been submitted for application of Research University Grant, UTM.

It has been adapted for this Research Methodology course)

A Research Proposal on

Unified Methodology for Damage Assessment of Structural Composites

By

Prof. Dr. Mohd Nasir Tamin

FACULTY OF MECHANICAL ENGINEERING UNIVERSITI TEKNOLOGI MALAYSIA 81310 UTM SKUDAI, JOHOR, MALAYSIA

March 2011

TABLE OF CONTENT

CHAPTER 1 1.1 INTRODUCTION 1.2 BACKGROUND AND RATIONALE 1.2.1 Research Objectives 1.3 RESEARCH PROBLEM AND HYPOTHESES 1.3.1 Statement of Research Problem 1.3.2 Research Questions 1.3.3 Research hypotheses 1.4 SIGNIFICANCE OF FINDINGS CHAPTER 2 2.1 INTRODUCTION 2.1.1 Dependent Variables 2.1.2 Independent Variables 2.2 CONCEPTUAL MODEL 2.3 SCOPE OF STUDY CHAPTER 3 3.1 INTRODUCTION 3.2 RESEARCH DESIGN 3.3 SAMPLING DESIGN 3.4 RESEARCH EQUIPMENT 3.5 DATA COLLECTION 3.6 DATA ANALYSIS CHAPTER 4 4.1 INTRODUCTION 4.2 RESEARCH SCHEDULE List of References

CHAPTER 1 1.1 INTRODUCTION Fiber-reinforced polymer (FRP) matrix composites consists of thermoset or thermoplastic resin matrix reinforced by much stronger and stiffer fibers such as carbon, glass and UHMW polyethylene fibers. Carbon fiber-reinforced polymer (CFRP) composites are commonly employed in advanced structural applications including the skin of aircraft wings, stringers, rotor blades and molded beams. The increasing use of CFRP composites is derived from its high strength-to-weight ratio, high specific modulus and flexible design through sequencing of the pre-impregnated laminates. Typical loading in these structures often involves tensile and lateral bending of the composite laminates, both transient and fatigue. Several damage and fracture modes observed in CFRP composite panels include matrix cracking, fiber/matrix interface debonding, fiber fracture, fiber pull-out and interface delamination. Thus, reliability of a CFRP composite structure under such load conditions depends on the continual process of damage initiation and subsequent damage propagation to catastrophic fracture. In this respect, development of a unified predictive approach for reliability assessment of CFRP composites is of prime importance. The unified approach should account for the various damage and fracture modes in the design phase with the aid of numerical modeling and validation testing of the composite sample coupons.

1.2 BACKGROUND AND RATIONALE Fiber-reinforced polymer (FRP) matrix composites offer an alternate replacement material to high-strength metals. In the transportation sector, the use of light-weight CFRP composites in airframe, automotive and railcar structures leads to improved (lower) fuel consumption and/or increased payload. The growth in use of CFRP composites from 15% in 1990 (A320) to over 50% in 2010 (A380) for airframe structures and high lift components is demonstrated [1]. The composites resistance to environmental corrosion is an added advantage over their metallic counterpart. This intrinsic property is appealing to applications in construction industry for bridges and wastewater and chemical storage tanks. Other property such as the composites transparency to radar is valuable for stealth applications. In addition, CFRP composites offer flexibility in design through sequencing of pre-impregnated laminates for tailored strength and stiffness properties in particular loading direction. The relative low consolidation or curing temperature further lower the manufacturing cost of the part. The challenge is to consider the design tradeoffs in choosing the lightest material that still meet the strength requirements of the part while maintaining the cost effectiveness. The reduced through-life support cost of the composite structures must also be considered. This calls for evaluation of the materials resistance to quasi-static, impact and fatigue loading along with mechanical damage evolution. Simple tests of the laminated composite coupons such under tension, compression, shear and flexural loading are useful to measure intrinsic properties of the composites [2-4]. Fracture tests on pre-cracked samples are useful to establish fracture toughness and critical energy release rates of the composites in Mode I and II loadings [5]. However, specially-designed specimen, jigs and fixtures, and environmental chamber are required to establish mixed-mode loading effects [6], mean stress effects on fatigue life and moisture conditioning effects in accelerated testing [7].

Failure process in CFRP composites is a complex phenomenon. Different failure modes such as matrix yielding, matrix cracking, fiber/matrix interface debonding, fiber pull-out, fiber fracture and inter-ply delamination could occur in isolation or synergize simultaneously. Interface delamination is particular interest in view of the relatively weak ply-to-ply interface strength and the large interface shear stresses developed during loading. Interface delamination failure leads to significant loss of the load-carrying capacity and occurs in the absence of any visible damage of the CFRP composite [8]. Such critical delamination failure process could be accounted for in the design phase with the aid of numerical modeling and validation testing of CFRP composite specimens. Several materials models have been proposed and examined for predicting the composite strength with the different types of constituent defects. These include stress-based failure models [9-11] and strain-based criteria [12,13] for matrix cracking and fiber fracture. The progression of each defect under fatigue load cycles dictates the useful life of the part. In this respect, cohesive zone model has been formulated for predicting ply interface delamination damage initiation and subsequent propagation under monotonic loading condition [14,15]. The damage-based model employing virtual crack closure concept is introduced to account for load reversals in fatigue failure of the laminates [16,17]. However, the simultaneous occurrence of multiple failure modes in a composite part under loading could not be represented by any of these models. To this end a unified approach based on continuum damage mechanics concept is proposed to account for the synergy effects of multiple failure mechanisms in CFRP composites. Implementation of the newly-developed damage-based models into finite element codes [eg. 18] and availability of vast computing power would yield a validated platform for addressing airworthiness issues regarding safety and reliability of CFRP composite airframe structures. 1.2.1 Research Objectives 1. To identify dominant damage mechanisms and their interactions during failure process of CFRP composite laminates. 2. To determine mechanical and fracture properties of CFRP composites and their damage evolution characteristics as function of lamina sequence. 3. To demonstrate the predictive capability of a unified materials model for deformation and damage (life) of CFRP composites under general loading using finite element method. 1.3 RESEARCH PROBLEM AND HYPOTHESES 1.3.1 Statement of the Research Problem How could the occurrence of multiple failure modes in CFRP composites be quantified for damage tolerance and reliability of the composite parts? 1.3.2 Research Questions 1. What are dominant damage mechanisms in CFRP composites under reliability load conditions. 2. What are available material models for deformation and failure of CFRP composite? 3. How could these models be integrated into a unified approach for life prediction of the composite part? 4

4. What is the minimal testing program for establishing model parameters and damage evolution characteristics? 5. How could the proposed unified model be validated for damage tolerance and reliability of CFRP composite part? 1.3.3 Research Hypotheses Aircraft parts such as wing, fuselage and tail skins are likely to be subjected to lateral bending and in-plane loading. Lateral bending load could initiate interface delamination between the plies since the strength of interplay is relatively [ref]. However, interface delamination crack introduces local stress concentration that could cause fiber fracture during subsequent fatigue load cycles. In-plane tensile loading could cause high shear stress along selected fiber orientation causing matrix yielding and cracking. Cohesive zone model is available for predicting interply delamination process[14]. Matrix yielding and fiber fracture can be predicted using Hashins models [10] and Tsai-Hill models [11]. The virtual crack closure model provides predictive capability for fatigue crack propagation in composites [17]. A damage mechanics framework combining deformation and failure will be formulated. The dominant failure mechanisms of matrix cracking/yielding, interface delamination and fiber fracture will be represented in a unified damage-based model. Criterion for damage initiation and damage evolution rule for a material point in the composite will be prescribed. This criterion and damage rule will be formulated based on stress invariants and hysteresis energy, respectively. The testing program must account for the determination of basic mechanical and fracture properties of the composite. Tension test determines modulus and strength properties while bending test (4-point) establishes bending stiffness. Fracture tests on pre-cracked sample in various loading configurations establish critical energy release rates for mode I and II along with mode mixity effects. Interrupted fatigue tests can be employed to monitor the evolution of damage in the composite specimen as function of loading. The unified predictive model for will be incorporate into commercial FE package (Abaqus). Validation of the unified approach can be carried out using a one-to-one simulation and tests of CFRP composite specimen under controlled loading conditions. Predictive capability for complex loading conditions is possible using biaxial loading and mixed-mode bending (MMB) specimen geometry. Validation aspects to be examined are prediction of correct failure modes, damage propagation characteristics and fatigue lives of the specimen/ parts. 1.4 SIGNIFICANT OF FINDINGS This project proposes the development of a framework for establishing CFRP composite laminates behavior under different loading conditions. The benefit of the extended framework is visible in providing guidelines on interpretation of data for conditions other than those under which they were obtained. Reliability test data generated through the proposed experimental program is indispensable during both initial material selection and detailed engineering design stage of CFRP composite structures. The outcome of the proposed research; a validated unified methodology for assessing composite failure process by the various damage mechanisms could be directly employed for predicting structural integrity of composite parts. This proposed project 5

is in-line with industry-led R&D theme in aerocomposite structural design and development under university-industry collaboration with the establishment of Aerostructure Manufacturing Innovation Center (AMIC) in Malaysia. The significance of composite research is reflected in a continual increase of EADS/Airbus average annual sourcing in Malaysia from USD 50m in 2004-2007 to USD 120m in 2010-2012 [Might, 2010].

CHAPTER 2 2.1 INTRODUCTION This chapter describes the aspect and dimensions of the research problem in adequate detail. 2.1.1 Dependent Variables Damage - the extent of the composite materials degradation leading to failure or fracture of the structure. Indicators: Mechanisms - types or mode for failure as observed experimentally. Evolution - characteristic of the continuous increase of damage with time. Fracture - terminal value of damage.

2.1.2 Independent Variables Load - the applied force and bending moment to the composite specimen. Indicators: Magnitude - measurable size of the applied force or bending moment. Rate - changes in the applied load to the specimen per unit time. Frequency - rate of load reversals for fatigue loading. Layups - sequence of ply orientations making up the laminates

2.2 CONCEPTUAL MODEL The interactions among dependent and independent variables of the research (cause-andeffect) are illustrated in Figure 1. Fracture

Damage

Layups

Rate

Load Figure 1 Conceptual Framework

2.3 SCOPE OF STUDY The scope of study covers the followings: 1. Carbon fiber-reinforced polymer (CFRP) composite laminates with three different lay-ups will be used as representative materials. 2. Mechanical and fracture properties will be established in accordance to ASTM standards or equivalent. These tests will be conducted at room temperature and laboratory air/ humidity environment. 3. Materials damage models for independent failure mode will be developed based on existing damage-based formulations, with updates as required. 4. New unified damage-based model will be constructed, evaluated for CFRP composites and validated using data from standard test procedures on complex loading. 5. Finite element software, Abaqus ver. 6.9 or newer will be used for integrating the unified model.

CHAPTER 3 3.1 INTRODUCTION The methodology of the proposed research including operational framework, sampling design, required research equipment, data collection and analysis is described in adequate detail in this chapter. 3.2 RESEARCH DESIGN The operational framework of the proposed research is illustrated in Figure 2. Each major activity is briefly described as follows: CFRP composite plates will be acquired from ISAT, France (under UTM-Univ. of Burgundy MoU) for three different layups: [0]4 reference unidirectional fiber laminates [45/-45/45/0/-45/0/0/45/0/-45/45/-45] anti-symmetric laminates [0/0/45/-45]S typical symmetric layups used in aerostructures Specimen design and testing will follow ASTM standard or equivalent. Jig & fixture for composite testing will be designed and fabricated, as needed Mechanical Testing Program consists of the following tests: - Quasi-static tests including tension, compression and 4-point bend tests to determine stiffness and strength. - Fracture mechanics tests including Mode I test using double cantilever beam (DCB) specimen and Mode II interlaminar shear fracture test using end-notched fracture (ENF) specimen. These tests determine energy release rates in respective mode. - Interrupted fatigue tests, combined with ultrasonic defect detection establishes damage evolution characteristics of the specimen. Validation Testing Program consist of quasi-static tests of the samples under combined loading to fracture (Mode I and Mode II): - Tension-tension biaxial loading for response under in-plane loading condition - Mixed-mode Bending (MMB) test to establish interaction of different modes of fracture (tension and shear) Fractographic Analysis is performed on post-test/ fractured samples to identify dominant operating damage mechanisms. Numerical Model Development is aimed at producing a general purpose unified model for predicting behavior and failure (life) of CFRP composite laminates under expected loading of the composite part. The scope covers: - Reviewing and updating existing continuum damage model for matrix yielding/ cracking and fiber fracture, and cohesive zone model for ply interface delamination. - Extraction of model parameters from results of test data. - Validation of each material model by comparing FE prediction with measured behavior.

New methodology for integrating both models into a unified predictive damage-based approach for CFRP composites.

Integration of the unified damage-based model into commercial finite element code will carried out in the final phase of the project. The validity and predictive capability of this methodology in assessing damage of CFRP composite parts will be demonstrated.

CFRP composite panels [0]4 (ref.) [45/-45/45/0/-45/0/0/45/0/-45/45/-45] [0/0/45/-45]s ] Specimen and fixture design and fabrication Establish initial damage/defects

Mechanical Testing Program Quasi-static tests Fracture mechanics tests Interrupted fatigue tests Validation Testing Program Biaxial loading Mixed-mode bending test Fractographic Analysis

Numerical Model Development Continuum damage Cohesive zone Extraction of model parameters

Validation of Materials Models

Integration of Unified Damage-based Model into FEA code -Demonstrate predictive capability of the model

Figure 2 Operational research framework

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3.3 SAMPLING DESIGN Pre-fabricated mechanical defects or notches are introduced in the CFRP composite panel using Teflon tape inserted in designated inter-ply layers during lay-up process. Geometry of the sample coupons of the composites will be as suggested by ASTM standards for the respective tests. Aluminum end tabs will be used to provide grips of the specimen. 3.4 RESEARCH EQUIPMENT Testing equipment and facilities required for the proposed research are listed in Table 1. Table 1 List of equipment / facilities and their availability Universal dynamic testing machine, with 30 kN load cell Optical and Scanning electron microscope High performance computing facilities Abaqus Finite Element software Composite specimen fabrication Jig and fixture fabrication Portable Ultrasonic Detector (Lab-scale) Strength of Materials Lab, FKM Materials Engineering Lab, FKM HPC at CICT, UTM and KnowledgeGRID Malaysia at MIMOS, KL Computational Solid Mechanics Lab, FKM To be outsourced To be outsourced To be purchased

Special Equipment and Accessories: Name of equipment: Portable Ultrasonic Detector Estimated cost: RM 40,000 Justification: The ultrasonic detector is required for detecting the existence of cracks and crack-like defects in CFRP composite panels and specimens being examined. It is to be used for establishing initial materials integrity status of the composite. In addition, the ultrasonic detector will be continuously employed during fatigue testing of composite sample coupons to establish the evolution of internal damage (including interplay delamination) as function of applied load cycles. The resolution should be suitable for CFRP composite materials.

3.5 DATA COLLECTION Load and displacement data pairs will be recorded using an on-line data acquisition system equipped with the testing machine.

3.6 DATA ANALYSIS Measured data will be processed and analyzed using MatLab software or Excel spreadsheet.

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CHAPTER 4 4.1 INTRODUCTION The research plan and milestones are described in this chapter. 4.2 RESEARCH SCHEDULE The proposed duration of the research is 24 months, from 01 April 2011 to 31 March 2013. The research plan and milestones are shown in Table 2. Table 2 Project Gantt Chart ACTIVITIES Acquisition of CFRP composite plates Specimen and jig&fixture design and fabrication Mechanical Testing Program Validation Testing Program Damage-based Models formulation Finite Element simulations Integration of unified model into FE software Technology transfer activity X X Q1
Apr Jun 2011

Q2
Jul-Sept 2011

Q3
Oct-Dec 2011

Q4
Jan-Mac 2012

Q5
Apr-Jun 2012

Q6
Jul-Sept 2012

Q7
Oct-Dec 2012

Q8
Jan-Mar 2013

MILESTONES ID. M1 M2 M3 M4 Milestone description Completion of specimen and Jig&fixture design and fabrication Complete formulation of unified damage-based model Completion of mechanical testing and data analysis Completion of project validated unified predictive model Date 30 Sept. 2011 31 Mar. 2012 30 Sept. 2012 31 Mar 2013

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REFERENCES [1] Composite Materials for Aircraft Structures, A. A. Baker et al., eds., 2nd edition, AIAA Education Series, USA, 2004. [2] Standard Test Method for Tensile Properties of Polymer Matrix Composite Materials, ASTM Standard D3039/D3039M-95a. [3] Standard Test Method for Compressive Properties of Unidirectional or Crossply Fiber-resin Composites, ASTM Standard D3410/3410M-95. [4] Standard Test Method for Shear Properties of Composite Materials by the V-Notched Beam Method, ASTM Standard D5379/D5379M-93. [5] Mode I Interlaminar Fracture Toughness of Unidirectional Fiber-Reinforced Polymer Matrix Composites, ASTM Standard D5528, 1994. [6] Benzeggagh, M.L. and Kenane, M., Measurement of Mixed-Mode Delamination Fracture Toughness of Unidirectional Glass/Epoxy Composites with Mixed-Mode Bending Apparatus, Composites Science and Technology, Vol. 49, pp. 439-449, 1996. [7] Ciriscioli, P.R., Lee, W.I. and Peterson, D.G., Accelerated Environmental Testing of Composites, J. Composite Materials, Vol. 21, pp225-242, 1987. [8] Koloor, S.S.R., Abdul-Latif, A and Tamin, M.N., Mechanics of Composite Delamination under Flexural Loading, Key Engineering Materials, Vol., pp. 2011. [9] Sun, C.T. and tao, J.X., Prediction Failure Envelopes and Stress/Strain Behavior of Composite Laminates, Composites Science and Technology, Vol. 58, pp. 1125-1113, 1998. [10] Hashin, Z. and Rotem, A., A Fatigue Failure Criterion for Fiber Reinforced Materials, J. Composite Materials, Vol. 7, pp. 448-464, 1973. [11] Tsai, S.W. and Wu, E.M., A General Theory of Strength for Anisotropic Materials, J. Composite Materials, Vol. 5, pp. 58-80, 1971. [12] Hart-Smith, L.J., Prediction of the Original and Truncated Maximum Strain-Strain Failure Models for Certain Fibrous Composite Laminates, Composites Science and Technology, Vol. 58, pp. 1151-1178, 1998. [13] Eckold, G.G., Failure Criteria for Use in design Environment, Composites Science and Technology, Vol. 58, pp. 1095-1105, 1998. [14] Davila, C. G., Camanho, P. P. and Moura, M. F, Mixed-Mode Decohesion Elements for Analyses of Progressive Delamination, Proc. 42nd AIAA /ASME /ASCE /AHS /ASC Structures, Structural Dynamics and Materials Conf, Seattle, WA, pp. 1619, April 2001. [15] Turon, A., Camanho, P. P., Costa, J., and Davila, C. G., An Interface Damage Model for the Simulation of Delamination Under Variable-Mode Ratio in Composite Materials, NASA/TM2004-213277, VA, USA, 2004. [16] Krueger, R., The Virtual Crack Closure Technique: History, Approach and Application, NASA/CR-2002-211628, NTIS, VA, USA, 2002. [17] Xie, D. and Biggers Jr., S.B., Progressive Crack growth Analysis using Interface Element based on Virtual Crack Closure Technique, Finite Element in Analysis and Design, Vol. 42, pp. 977-984, 2006. [18] Abaqus ver 6.9, Simulia Inc. 13