A Ph.D.

Registration seminar
on
An Investigation on Failure and Fracture of Environmentally
Conditioned Fibre Reinforced Polymer (FRP) Composites
by
Kishore Kumar Mahato (514MM1002)

Under the Supervision

of
Prof. Bankim Chandra Ray
and
Prof. Krishna Dutta
Department of Metallurgical & Materials Engineering
National Institute of Technology, Rourkela-769008, India
August 2015
OVERVIEW OF PRESENTATION
• Introduction
• Applications of FRP Composites
• Literature survey
• Research Gap
• Motivation
• Objectives
• Experimental work done so far
• Results and Discussion
• Remarks and conclusions
• Works to be done
• References
• Road map
INTRODUCTION
Composite material - A composite is made from two or more constituent materials with
significantly different physical or chemical properties, that when combined, produce a material
with improved properties from the individual components
 Composite → Matrix + Reinforcement
 Matrix Phase → Soft, Ductile, Formable
 Reinforcement Phase → Strong, Stiff, Brittle
 Composite → Combination of properties of
both matrix and reinforcement phase.

Interface/Interphase – It is a common bonding between

two regions i.e. fiber and the matrix.
Fibre Reinforced Polymer (FRP) Composite
=Polymer Matrix + Fibre
Common types of FRP Composites –
 CFRP(Carbon Fibre Reinforced Composite)
 GFRP(Glass Fibre Reinforced Composite)
 KFRP(Kevlar Fibre Reinforced Composite)
 Hybrid Fibre Reinforced Composite
An Insight of interface/interphase
APPLICATIONS OF FRP COMPOSITES
 LITERATURE SURVEY
Author(Year)
Tarfaoui et.al (2008)
Compos. Sci. Technol
Khoathane et al.(2008)
J. Reinf. Plas. Compos.
Cornelia E. Demers
et.al(1998)
J. const. Build.
L.H. Li et al. (2008)
Proceedings of the 4th Asian
Regional Conference on
Geosynthetics
Sayer et.al(2009)
Compos. Part B
B.C. Ray et.al (2015)
Materials Design.
Materials used Work done Findings
E-Glass fibre/epoxy Loading rate sensitivity Material is highly
(SHPB) sensitive to fibre
orientation
Composites reinforced with Tensile strength and Strength increases with
bleached hemp fibers Young's modulus increase in loading rates.
E-Glass fibre reinforced polymeric Tension- tension axial Lower bound values are
composites fatigue observed.
(Stress ratios 0.05, 0.1,0.5
and 0.9)
Glass fibre reinforced polymer Creep tests No creep strain increasing
(GFRP) with the time.
Hybrid composite(Glass and Impact performance Increase in impact energy,
carbon fiber) major failure was fibre
fracture.
E-Glass fibre/epoxy Evaluation for in-situ Strength increases with
Carbon fibre/epoxy environment increase in the loading
Kevlar fibre/epoxy rate.
 RESEARCH GAP
 As there is a lack of literature and experimental work on the static
(tensile) and dynamic (fatigue), fracture and creep behavior of
different environmentally conditioned conventional and hybrid FRP
composites:
 The mechanical performance of environmentally
conditioned and unconditioned specimens will be studied
under varying loading and impact loading conditions.
 The study of failure of composites is a challenge and
further study of failure assessment is of greater challenge.
 With environmental conditioning is a matter of research ,
so we have taken steps to find cutting edge of the
composite.
 MOTIVATION
 Nowadays, the existing or conventional structural materials have been deteriorating at
an increasing and alarming rate and hence these structural parts are replaced by FRP’s.

 These materials can be used prolong and extend the service life of existing structures.

 Fibre reinforced Polymer matrix composites (FRP’s)

 FRP’s posses a wide area of applications starting from tiny toys to different critical high
performance aerospace components.

Excellent superlative properties such as

USE OF FRP IN 2020 TOKYO OLYMPICS
STADIUM
 High strength to weight ratio
 High specific strength and specific modulus
 Fatigue resistance
 Corrosion resistance
 High creep resistance
 Low maintenance cost and longer life span
The giant autoclave used for backing carbon
composites in Boeing 787
 OBJECTIVES
 Fabrication of different FRP composite with different volume fractions and
different fibres using the concept of fibre hybridization.
 Different environmental conditionings such as hygrothermal, thermal shock,
thermal spike and high temperature.
 Evaluation of their static tensile, fatigue, compressive and creep properties.
 Evaluation of mechanical performance at different loading rates and also
under impact conditions.
 Evaluation of different failure modes in different test configurations.
 Micro-characterization using electron microscopy (SEM, TEM) and FTIR to
support the bulk material behavior obtained from aforesaid mechanical
testings.
EXPERIMENTAL WORK DONE SO FAR
Reinforcement : Woven fabric E- Matrix : Epoxy (DGEBA) ,(Lapox L -
glass fibre 12); Hardener: Diamine (Lapox K-6)

Fabrication using Hand Lay-up process (fibre: matrix was 60:40 and 70:30 ,
pressure at 5kg/cm² and 20kg/cm² ,epoxy: hardener ratio 10:1)

Curing at 60°C for 20 minutes

Cutting samples for Tensile test ,ASTM D3039 standard and Post cured at 140°C
for 6 hrs.

Fibre vol. Fraction(60%) In-situ Fibre vol. Fraction(70%) In-situ

conditioning at 70°C, 90°C and 110°C conditioning at 70°C, 90°C and 110°C
with 10 min equilibration time with10 min equilibration time

Conditioned samples tested in INSTRON 5967 for Tensile test at

1,10,100,500,1000 mm/min loading rates.

Fractography analysis by SEM Transition temperature by DSC

 RESULTS AND DISCUSSION
Effects of temperature on glass fibre reinforced polymer (GFRP) composite

(a) (b)

At 1 mm/min, (VF) = 60% At 1 mm/min, (VF) = 70%

Load Vs displacement curves at RT(25 °C), 70 °C, 90 °C, 110 °C temperatures at 1 mm/min
loading rate; (a) Reinforcement content (VF) = 60%, (b) Reinforcement content (VF) = 70%
 RESULTS AND DISCUSSION (Cont’d….)
Effects of temperature on glass fibre reinforced polymer (GFRP) composite

(a) (b)

At 1000 mm/min, (VF) = 60% At 1000 mm/min, (VF) = 70%

Load Vs displacement curves at RT(25 °C), 70 °C, 90 °C, 110 °C temperatures at 1000 mm/min
loading rate; (a) Reinforcement content (VF) = 60%, (b) Reinforcement content (VF) = 70%
 RESULTS AND DISCUSSION (Cont’d….)
Effects of fibre volume fraction on glass fibre reinforced polymer (GFRP) composite
(a) (b)

At RT(25°C) At 70°C

(c) (d)

At 90°C At 110°C

Load Vs displacement curves at (a) RT(25 °C), (b)70 °C, (c) 90 °C, (d) 110 °C temperatures
at 1 mm/min loading rate with fibre volume fraction (VF) = 60% and 70% respectively.
 RESULTS AND DISCUSSION (Cont’d….)
Effects of fibre volume fraction on glass fibre reinforced polymer (GFRP) composite
(a) (b)

At RT(25°C) At 70°C

(c)

At 90°C

Load Vs displacement curves at (a) RT(25°C), (b)70°C, and (c) 90°C temperatures at
1000 mm/min loading rate with fibre volume fraction (VF) = 60% and 70% respectively.
 RESULTS AND DISCUSSION (Cont’d….)
Effects of loading rates on glass fibre reinforced polymer (GFRP) composite (VF) = 60%
(a) (b)

At RT(25°C) At 70°C

(c) (d)

At 90°C At 110°C

Load Vs displacement curves at (a) RT(25°C), (b)70 °C, (c) 90 °C, (d) 110 °C temperatures
at 1,10,100,500, 1000 mm/min loading rate with fibre volume fraction (VF) = 60%
 RESULTS AND DISCUSSION (Cont’d….)
Effects of loading rates on glass fibre reinforced polymer (GFRP) composite (VF) = 70%
(a) (b)

At 70°C
At RT(25°C)

(c) (d)

At 110°C
At 90°C

Load Vs displacement curves at (a) RT(25 °C), (b)70 °C, (c) 90 °C, (d) 110 °C temperatures
at 1,10,100,500, 1000 mm/min loading rate with fibre volume fraction (VF) = 70%
 FRACTOGRAPHY ANALYSIS
(a) (b)
Fibre Fractures
Matrix Fracture

Scanning electron micrographs (SEM) of glass/epoxy composite tested at 1 mm/min at room

temperature (25°C), VF =60%
 FRACTOGRAPHY ANALYSIS (Cont’d..)
(a) (b)
Delamination

Fibre Breakage

(C) Fibre/ matrix debonding (d)

Matrix Cracking

Scanning electron micrographs (SEM) of glass/epoxy composite tested at 1 mm/min at

(a)70°C, VF =60%, (b)70°C, VF =70%, (C)110°C, VF =60%, (d)110°C, VF =70%,
 FRACTOGRAPHY ANALYSIS (Cont’d..)

(a) (b)

Mirror

Hackle Mist

Mist Hackle
Mirror
Fiber pull-out

Scanning electron micrographs (SEM) of glass/epoxy composite tested at 1000 mm/min at

room temperature (25°C), VF =60%
 FRACTOGRAPHY ANALYSIS (Cont’d..)
Composite failure (b)
(a)

Fibre fracture

Fibre/ matrix debonding (d)

(c)

Scanning electron micrographs (SEM) of glass/epoxy composite tested at 1000 mm/min at

(a)70°C, VF =60%, (b)70°C, VF =70%, (C)110°C, VF =60%, (d)110°C, VF =60%,
Differential scanning calorimetry (DSC) analyses

The glass transition temperature (Tg) of glass/epoxy at 25°C, 70°C, 90°C and 110°C
for two volume fractions of fibers i.e. 60% and 70% respectively.
REMARKS AND CONCLUSIONS
 The load carrying capacity of both the composites system increases with the increase in
loading rate (except 1000 mm/min) at all temperatures under investigation. At high loading
rate the response of the composite is primarily governed from the fibre phase and increase
in load carrying capacity can be attributed to fibre dominated mechanical response.
 Temperature has significant effect on the load-displacement characteristics of both GFRP
systems at different loading rates. At low loading rate, for 60% fibre vol. fraction
composite, as the temperature increases the ultimate tensile strength (UTS) tends to
decrease, while the UTS remains almost similar at 25°C and 90°C when the tests
conducted at 1000 mm/min loading rate.
 For 70% fibre volume fraction composite, as the testing temperature increases to 70°C the
UTS also increased and with further increase in temperature it continues to decrease and at
110°C the lowest value was observed. The changes in UTS at different temperatures are
nearly similar for both low and high loading rates.
 The effect of fiber volume fraction at 1mm/min shows that at room temperature, 70% fibre
vol. fraction of composite exhibit higher peak load value but at high temperatures both the
composite systems yield nearly equal load carrying capacity, but the displacement is lower
in case of 60% vol. fraction of composite.
 REMARKS AND CONCLUSIONS
 Various dominating failure modes comprehensively includes mirror, mist and hackle, fibre
pullout, complete composite failure i.e. fibre breakage and matrix cracking itself by means
of larger crack formation and propagation and also sometimes outcrop of resin itself from
the neat epoxy matrix, fibre/matrix debonding, brittle fracture of fibres, and delamination.
 There was no significant changes found in the glass transition temperature (Tg) for the
conditioned and unconditioned specimens with two volume fractions of fibres in the FRP
composite system.
 WORKS TO BE DONE
 The future research work will be concentrated on the evaluation of mechanical behaviour
of glass/epoxy, carbon/epoxy, glass/carbon/epoxy hybrid and Kevlar/ epoxy composites
exposed to different environments such as: hygrothermal, thermal shock, thermal fatigue,
thermal spike and high temperature with different loading rates.
 Focus will also be given to improve the strength and toughness of FRP composites by the
concept of hybridization and their environmental durability and loading rate sensitivity will
be assessed.
 To know the various failure modes such as fatigue, creep and impact behavior of
environmentally conditioned FRP composites will be studied.
 Evaluation of different failure micro-mechanisms will be carried out for composites
fractured in different test configurations. Further the micro-characterization will be carried
out using electron microscopy (SEM, TEM) and FTIR to support the bulk material
behavior obtained from aforesaid mechanical testings.
 To understand the viscoelastic behaviour of FRP composites at high, low and humid
temperatures dynamic mechanical thermal analyses (DMTA) will be performed.
 Differential scanning calorimetry (DSC) tests will be performed to predict the transition
temperature of the polymer phase i.e. the matrix phase.
 REFERENCES
 Ray B. C. and Rathore D., Durability and integrity studies of environmentally conditioned
interfaces in fibrous polymeric composites: Critical concepts and comment Adv. Colloid
Interface Sci. 209, 68–83, 2014.
 Drzal L. T., Rich M. J., Koenig M. F., and Lloyd P. F., Adhesion of Graphite Fibers to Epoxy
Matrices: II. The Effect of Fiber Finish, J. Adhes., vol. 16, no. 2, 133– 152, 1983.
 Kendall K., Foreword, in Engineered Interfaces in Fiber Reinforced Composites, J.K. Kim, Y.W.
Mai, and Y.-W. Mai, Eds. Oxford: Elsevier Science Ltd, p. v. 1998.
 Clinard F. W. Jr. and Hurley G. F., Ceramic and organic insulators for fusion applications,‖ J.
Nucl. Mater., vol. 103, 705–715, 1981.
 Jang C., Lacy T. E., Gwaltney S. R., Toghiani H., and Pittman Jr. C. U., Interfacial shear
strength of cured vinyl ester resin-graphite nanoplatelet from molecular dynamics simulations, J
Polymer, vol. 54, no. 13, 3282–3289, 2013.
 Peterson A. M., Jensen R. E., and Palmese G. R., Thermoreversible and remendable glass–
polymer interface for fiber-reinforced composites, J. Compos. Sci. Technol., vol. 71, no. 5, 586–
592, 2011.
 Davies R.G., Magee C.L., The effect of strain-rate upon the tensile deformation of materials, J.
Eng. Mate. Technol.; 97:151–155, 1975.
 Daniel IM, Liber T. Testing of fiber composites at high strain rates. In: Proceedings of the 2nd
international conference on composite materials, ICCM II, Toronto, Canada; 1003–1018,1978.
 PUBLICATIONS AND CONFERENCES
 K. K. Mahato, M. J. Shukla, D. S. Kumar and B. C. Ray, “In- service Performance of Fiber Reinforced
Polymer Composite in Different Environmental Conditions: A Review,” J. Adv. Res. Manuf. Mater. Sci.
Metall. Eng., vol. 1, Issue no. 2, pp. 55–88, Sep. 2014.
 D. S. Kumar, M. J. Shukla, K. K. Mahato, D. K. Rathore, R. K. Prusty, and B. C. Ray, “Effect of post-
curing on thermal and mechanical behavior of GFRP composites,” in IOP Conference Series: Materials
Science and Engineering, 2015, vol. 75, p. 012012.
 M. J. Shukla, D. S. Kumar, K. K. Mahato, D. K. Rathore, R. K. Prusty, and B. C. Ray, “A comparative
study of the mechanical performance of Glass and Glass/Carbon hybrid polymer composites at different
temperature environments,” in IOP Conference Series: Materials Science and Engineering, 2015, vol. 75,
p. 012002.
 K. K. Mahato*,M J Shukla, D S Kumar , D K Rathore, R K Prusty, B.C. Ray, A Comparative study of the
mechanical performance of glass and glass/carbon hybrid fiber polymer composites at different
temperature environments. 4th National Conference on Processing and Characterization of Materials 5-6th
December 2014.
 K. K. Mahato*, D.K.Rathore, B.C.Ray. Effect of Thermal Spike Conditioning On Mechanical Behaviour
of FRP Composites at Different Loading Rates. 7th National symposium for material research scholars
MR15, IIT Bombay

WORKSHOP ATTENDED
 One day workshop on “Experimental methods in stress analysis and fatigue failures”, 22nd August
2015, Department of Mechanical Engineering, NIT Rourkela.
 ROAD MAP
PERIOD
PLAN OF WORK
July 2014 Jan 2015 July 2015 Jan 2016 July 2016 Jan2017 July 2017 Jan 2018
Semester
Objectives/Task to to to to to to to to
Dec 2014 June 2015 Dec 2015 June 2016 Dec 2016 June 2017 Dec 2017 June 2018

Course Work

Literature Survey

Experimental Work

Analysis of Experimental
work

Writing of Manuscript

Writing of Thesis and

Submission