The Structural Integrity of Carbon Fiber Composites: Fifty Years of Progress and Achievement of the Science, Development, and Applications PDF
Preview The Structural Integrity of Carbon Fiber Composites: Fifty Years of Progress and Achievement of the Science, Development, and Applications
Peter W.R. Beaumont Constantinos Soutis E ditors The Structural Integrity of Carbon Fiber Composites Fifty Years of Progress and Achievement of the Science, Development, and Applications The Structural Integrity of Carbon Fiber Composites Peter W.R. Beaumont • Constantinos Soutis Editors The Structural Integrity of Carbon Fiber Composites Fifty Years of Progress and Achievement of the Science, Development, and Applications 123 Editors PeterW.R.Beaumont ConstantinosSoutis DepartmentofEngineering AerospaceResearchInstitute UniversityofCambridge TheUniversityofManchester Cambridge,UK Manchester,UK ISBN978-3-319-46118-2 ISBN978-3-319-46120-5 (eBook) DOI10.1007/978-3-319-46120-5 LibraryofCongressControlNumber:2016956571 ©SpringerInternationalPublishingSwitzerland2017 Thisworkissubjecttocopyright.AllrightsarereservedbythePublisher,whetherthewholeorpartof thematerialisconcerned,specificallytherightsoftranslation,reprinting,reuseofillustrations,recitation, broadcasting,reproductiononmicrofilmsorinanyotherphysicalway,andtransmissionorinformation storageandretrieval,electronicadaptation,computersoftware,orbysimilarordissimilarmethodology nowknownorhereafterdeveloped. Theuseofgeneraldescriptivenames,registerednames,trademarks,servicemarks,etc.inthispublication doesnotimply,evenintheabsenceofaspecificstatement,thatsuchnamesareexemptfromtherelevant protectivelawsandregulationsandthereforefreeforgeneraluse. Thepublisher,theauthorsandtheeditorsaresafetoassumethattheadviceandinformationinthisbook arebelievedtobetrueandaccurateatthedateofpublication.Neitherthepublishernortheauthorsor theeditorsgiveawarranty,expressorimplied,withrespecttothematerialcontainedhereinorforany errorsoromissionsthatmayhavebeenmade. Printedonacid-freepaper ThisSpringerimprintispublishedbySpringerNature TheregisteredcompanyisSpringerInternationalPublishingAG Theregisteredcompanyaddressis:Gewerbestrasse11,6330Cham,Switzerland Preface It may have escaped the notice of the casual observer and user of carbon fibre productssuchasthetennisracketorgolfclubthatcarbonfibrehasbeenaroundnow for50 yearsfromthose ‘headydays’of the 1960swhen, asa matchboxcuriosity, the short black ‘prickly’ fibre was worth more than its ‘weight in gold’. Within a year,thefibrewasbeingproducedascontinuousfibreinbundlesortowsof10,000 individual filaments wound onto spools that could be thrown like an American footballtothebackofcollegelecturetheatres,thefibreunravellingasitspedfrom thespeaker’shandovertheheadsofexcitedengineeringstudents. The discovery of this high-strength, high-stiffness, lightweight material that could be woven into fabric had returned us to those factories of northern British townsoftheeighteenthandnineteenthcentury.Fibreinandproductoutthroughthe factoryfrontdoor,wehavenowarrivedwherematerialprocessingandmanufacture, designandfabricationofthefinalproductcannowtake placeunderoneroof.We havearrivedbacktothefactoryofthefuture. It is fitting on the occasion of 50 years of carbon fibre to place on record the historical stages of the development of structural carbon fibre composites (and other fibre composites), as well as premonitory things that happened on the way. An impressionistic map, if you like, of the present state of the art for readers coming new to the field as well as those ensconced in research and development of composite materialsand large composite structures,from the emergenceof the scienceofcompositesandtheevolutionofanumberofneighbouringdisciplines. In the ‘blink of an eye’, we have in composite materials discovered a clearly defined and distinct discipline, which in practice doubles up as a multidiscipline withasubstantialnumberofindependent‘branches’,eachonewithitsmultifarious journalsand textbooks,read by practicing materials scientists and engineersalike who communicate with each other on that basis. The discipline of the materials science and engineering of contemporary composite materials has emerged from thosesmallbeginningsonehalfcenturyago. But this book is in no sense a textbook of carbon fibre composite materials alone. In this single volume, the authors have produced an impressionistic map of the present state of the science and mechanics of composite materials, seen as v vi Preface a pointillistic portrait of the discipline of composites, to be viewed from a slight distance. But what defines composite materials science and links it to traditional engineering disciplines? Perhaps the way to address this question is by means of whatphilosopherscallan ostensive definition,relyingonanalogicalorcase-based reasoning. In other words, the chapters presented here are an essay in ostensive definitionalbeitacomprehensiveone. Throughout these chapters, we observe the materials scientist and engineer workingatseverallevelsoforganisation,eachofwhichisunderpinnedbythenext level. This feature is central to the subject of composite materials—the concept of ‘architecture’ as the defining theme that connects composite materials science and engineering across orders of magnitude of size. At some point on this scale canbedefinedtheconceptofmeso-structure,atermfrequentlyusedbymodellers and simulators of composites that level between the microscopic level and the macroscopicappearancefromtheviewpointoftheengineer. The author of each chapter starts from their own personal viewpoint, delving into the natural characteristics and behaviour of a particular class of engineering material reinforced in some way by carbon fibre or another fibre of those high- performance fabrics, probing and examining such concepts and relationships as structural architecture and design from the very small to the very large. What emerges is the evolution of a number of neighbouring disciplines in mechanical designandprocessing:experimentationandanalysis,mathematicalandcontinuum modelling, constitutive and physical modelling (or micromechanics or damage mechanics), computational mechanics and virtual simulation aided by computer power. Fine-scale phenomena become embedded in calculations representing larger- scalebehaviour,arrivingatintelligentmechanicaldesignbasedupontheapplication of the principles of integrated multi-scale mechanics and hierarchicalmodels and analyses. They all share certain characteristics in terms of hierarchy in which material constitutive properties are passed on from one model to the next via inheritancethroughoutthecompletemanufactureanddesignprocess. Throughout the book, major themes range from descriptions and analyses of nano- and micro-scale phenomenathat affect composite material behaviourat the metrelevelof size and above.Theyincludethe natureof cracksthatnucleateand growtothreatenthesafetyoflargeengineeringcompositestructures,fundamental materialissuesthataffectcompositeweaknessandcompromisecompositestrength andsolutionstochallengingmaterialproblemsthathinderthesafe exploitationof largecompositestructures.Thisrequiresanin-depthknowledgeandunderstanding of the deformationand cracking processes in compositesbest detected and moni- toreddirectly,tracingdamagingmechanismsandstructuralchangesovertime. But that which draws the threads of chapters together is an understanding of the structural integrity of the composite. By means of careful experimentation and sound analysis, this ultimately leads to successful forecasting of the limits of materialperformanceontheonehandanddefinestheconditionsforsafeoperation ofcompositestructureontheotherfrom‘cradletograve’. Preface vii RobertHookewrites,inhisbookMicrographia(1665),animprintoftheRoyal SocietyofLondon: AndIhaveoftenthoughtthatprobablytheremightbeawayfoundouttomakeanartificial glutinouscompositionmuchresemblingifnotfullasgood,naybetterthanthatexcrement or whatever substance it might be out of which thesilkworm draws his clew. If such a compositionwerefounditwerecertainlyaneasymattertofindveryquickwaysofdrawing itintosmallwires*foruse.Idonotmentiontheuseofsuchaninventionnorthebenefitthat islikelytoaccruetothefinder,theybeingfullyobvious.ThishintmayIthereforehopeto givesomeinquisitivepersonanoccasionofmakingsometrialswhichifsuccessfulIhave myaimandIsupposehewillhavenooccasiontobedispleased. (cid:129) OldEnglishw¯ır;Germanicorigin,probablythebaseofLatinviere‘plait,weave’ PeterW.R.Beaumont Cambridge,UK ConstantinosSoutis Manchester,UK June2016 Acknowledgements First of all, we want to acknowledge our debt to the late Professor Tony Kelly, materials scientist and friend, who through his great depth of understanding of compositematerialsgavesageadviceandencouragementfromtheverybeginning whentheideaofthisbookbegantocrystallise2yearsago. We thank the authors of the chapters for spending so much of their valuable time and support throughout the process of preparing this book. They are to be congratulated in bringing together the basic concepts of physical and micromechanics modelling and mathematical and continuum modelling and in reconciling them with each other to reappraise current design practice and future designstrategiesandtodevelopandvalidaterisk-basedassessmentmethodologies. We thank them for their cooperation throughout this project and their writing of suchexcellentchapterscontainedherein. Theeditors:ConstantinosSoutis(left)andPeterW.R.Beaumont ix Contents PartI 1 50YearsinCarbonFibre,60YearsinComposites..................... 3 RobertD.Adams 2 ‘ButHowCanWeMakeSomethingUsefulOutofBlack String?’TheDevelopmentofCarbonFibreComposites Manufacturing(1965–2015) .............................................. 29 KevinPotter 3 BoronFibertoCarbonFiber.............................................. 59 CarlT.Herakovich 4 SerendipityinCarbonFibres:InterfacesandInterphases inComposites ............................................................... 71 FrankR.Jones PartII 5 Nano-EngineeredHierarchicalCarbonFibresandTheir Composites:Preparation,PropertiesandMultifunctionalities........ 101 HanZhang,EmilianoBilotti,andTonPeijs 6 Nano-engineeredCarbonFibre-ReinforcedComposites: ChallengesandOpportunities............................................. 117 LarissaGorbatikhandStepanV.Lomov 7 ANano-micro-macro-multiscaleModelforProgressive FailurePredictioninAdvancedComposites............................. 137 SamitRoy,AbhishekKumar,andShiboLi 8 Carbon Fibre-Reinforced Polymer Laminates withNanofiller-EnhancedMultifunctionality........................... 171 WeiHan,YouhongTang,andLinYe xi xii Contents 9 AnalysisModelsforPolymerCompositesAcrossDifferent LengthScales................................................................ 199 PedroP.CamanhoandAlbertinoArteiro PartIII 10 Microscale Characterization Techniques ofFibre-ReinforcedPolymers............................................. 283 M.Herráez,F.Naya,C.González,M.Monclús,J.Molina, C.S.Lopes,andJ.LLorca 11 FibreDistributionandtheProcess-PropertyDilemma ................ 301 JohnSummerscales 12 AnalysisofDefectDevelopmentsinCompositeForming .............. 319 P.Boisse,N.Hamila,andA.Madeo PartIV 13 DeformationMechanismsofCarbonFibresandCarbon FibreComposites........................................................... 341 RobertJ.Young 14 MicromechanicalEvidencesonInterfibreFailureofComposites .... 359 FedericoParís,ElenaCorrea,andVladislavManticˇ 15 ProgressiveDamageinFibre-ReinforcedComposites: TowardsMoreAccurateandEfficientComputational ModellingandAnalysis.................................................... 391 B.Y.ChenandT.E.Tay 16 Predicting Propertiesof Undamaged and Damaged CarbonFibreReinforcedComposites.................................... 425 L.NeilMcCartney PartV 17 CompositesToughenUp! .................................................. 471 IvanaK.Partridge 18 SlowCrackinginCompositeMaterials:Catastrophic FractureofCompositeStructures........................................ 489 PeterW.R.Beaumont 19 FiniteFractureMechanics: A UsefulTooltoAnalyze CrackingMechanismsinCompositeMaterials......................... 529 E.Martin,D.Leguillon,andN.Carrère
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