mda/cerf: durability study fatigue task group john j. lesko kenneth l. reifsnider stephan p. phifer...
TRANSCRIPT
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MDA/CERF: Durability StudyFatigue Task Group
John J. LeskoKenneth L. Reifsnider
Stephan P. PhiferCharles E. BakisAnthony Nanni
Clem Heil
ASME 2000 International Mechanical Engineering Congress & Exposition, November 2000
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Fatigue Issue Not Covered in This Talk
?
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Fatigue Failure Mechanisms
Fatigue-Life Diagram proposed by Talreja
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Fatigue - Overview
•Failure Mechanisms
•Fiber
•Matrix
•Residual Cure Stress
•Interface - Sizing
•Laminate
•Processing
Material & Processing Effects
•Frequency/Creep
•Hygrothermal •Temperature
•Acid/Base/Electrolyte
Environmental & Testing Effects
Interactive Effects
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Material Effects• Fatigue Failure Mechanisms
• Fiber
•E-glass, carbon/graphite, Kevlar
•Matrix
•Brittle, toughened
• Interface
•Compatible and non-compatible sizings
• Laminate
•Woven, stitched, and unidirectional
•Stacking sequence - 0°, ±45 °, 90° plies
• Processing Type
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FIBERS - (0/90°)s
• Gathercole, Reiter,Adam, Harris 1994, IJ of Fatigue, v. 16, no. 8, p.523.
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FIBERS - Tensile Stress Fatigue E-Glass
• Demers, Cornelia. E. 1997 The National Seminar on Advanced Composite Material Bridges, May 5-7.
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0
10
20
30
40
50
60
70
80
90
100
1.0E+01 1.0E+02 1.0E+03 1.0E+04 1.0E+05 1.0E+06 1.0E+07 1.0E+08
# cycles
% U
ltim
ate
Tens
ile S
treng
th
Dry
Salt
Wet
run out
1 decade
11% UTS
Normalized Fatigue Performance of Glass/Vinyl Ester
F. McBagonluri, K. Garcia, M. Hayes, N. Verghese, & J. J. Lesko, "Characterization of Fatigue and Combined Environment on Durability Performance of Glass/Vinyl Ester Composite for Infrastructure Applications" International Journal of Fatigue, Vol. 22, Issue 1, 2000, pp. 53-64.
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Glass Composite Fatigue1. Unidirectional glass/epoxy,
vf=0.52. Unidirectional glass/epoxy,
vf=0.333. Unidirectional glass/epoxy,
vf=0.164. 0°/90° glass5. 30-40% glass in
poly(hexamethylene adipamide), injection molded
6. 30-40% glass in polycarbonate injection molded
7. 30-40% glass in polyphenylenesulfide injection molded
8. 30-40% glass in poly(amide-imide) injection molded
9. Chopped-strand mat polyester10. Sheet molding compound
(smc) of rubber-modified epoxy
11. SMC, rubber-modified epoxy12. SMC, r5013. 0°/±45 ° /90° glass/epoxy14. Chopped-strand mat
polyester
Mandell, J. F., 1978, “Fatigue Behavior of Fibre-Resin Composites,” Developments in Reinforced Plastics 2, Properties of Laminates, Ed. G. Pritchard.
0200400600800
10001200140016001800
0 50 100 150
Slope S-N (MPa/Decade)
Str
engt
h (M
Pa)
Mandell's
As-received Extren
Aged Extren (Water)
Aged Extren (Salt)
UTS/B =10.7
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Mechanism: Fatigue of Glass Composites
• Crack growth in the fiber dominates the failure process
• Accumulation of damage is accounted for in crack growth that takes place based on the fractional time spent at a damaging stress level
NIAK
dt
da aYKI
2N
1Nt
0 ultult
r dt)t(
C1
Glass fiber remaining strength given a (t)
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Fatigue Simulation & Experiment
UCFR - unidirectional continuous fiber/epoxy
UCMFR - unidirectional & continuous strand mat fiber/vinyl ester
S-N Slope (%UTS/decade)Data: 10.2 and 13 Predictions: 12 to 14
0
0.2
0.4
0.6
0.8
1
1.2
1.E+00 1.E+02 1.E+04 1.E+06 1.E+08
# cycles
App
lied
Stre
ss/U
TS
UCFR10 Hz (Model)5 Hz (Model)2 Hz (Model)UCMFR
F. McBagonluri, G. Foster, S. Case, W. Curtin, & J. Lesko, “ Simulation Of Fatigue Performance Of Polymeric Composites For Infrastructure Applications,” Simulation of Fatigue Performance of Polymeric Composites for Infrastructure Applications ASME IMECE 98, Anaheim CA, Nov 1998
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Matrix & Sizing Effects
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Matrix Effects - S-N Curves for E-glass Laminates
• Konur & Matthews 1989, Composites, V.20, No. 4, July 1989.
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Sizing & Matrix Toughening Effects
• Salvia, Fiore, Fournier & Vincent I.J. of Fatigue, 1997,V.19 No.3, p. 253.
BNA
NBA
oo
10
10max
log
log
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Sizing Effects•EP - Epoxy Sizing
•MP - Multi-pupose sizing
•Epoxy Resin
• Salvia, Fiore, Fournier & Vincent I.J. of Fatigue, 1997,V.19 No.3, p. 253.
10max logNBA
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Pultruded AS-4/Derakane 411-35 LI: Sizing Effect
0
50
100
150
200
250
100 1000 10000 100000 1000000 10000000Number of Cycles
Phenoxy Sizing
G' Sizing
Run out
Input: R=0.1 Unidirectional Fatigue Data
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Processing Effects
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Process Type Effects
•FW - Filament Winding
•PMC - Prepreg Press Molding
•P - Pultrusion
• Salvia, Fiore, Fournier
& Vincent I.J. of Fatigue, 1997,V.19 No.3, p. 253.
BNAoo 10log
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Process & Laminate Effects - Pultruded CP, Prepreg CP & Woven
0
0.2
0.4
0.6
0.8
1
1.E+03 1.E+04 1.E+05 1.E+06 1.E+07Fatigue Cycles (N)
No
rmal
ized
Lam
inat
e T
ensi
le
Fat
igu
e S
tres
s
Pultrude (0/90°)5T Vinyl Ester
Pultrude (0/90°)3S Vinyl Ester
Mandell (0/90°)S Epoxy
Adams (0/90°)S Epoxy
Mandell Epoxy 181 Woven
• Phifer 1998, Thesis Virginia Tech. http://scholar.lib.vt.edu/theses/available/etd-013199-185939
Laminated
Stitched or Woven
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Testing & Environmental Effects
•Testing•Mean Stress & R - Ratio
•Frequency
•Environmental•Hygrothermal
•Temperature
•pH Effects
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Frequency & Mean Stress
Effects
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Static vs. Dynamic Fatigue
•Mandell & Meier 1983 ASTM STP 813 p.60
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• Gathercole, Reiter, Adam, Harris 1994, IJ of Fatigue, v. 16, no. 8, p.523.
Test Effects: R - ratio
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Test Effects: R - ratio
• Adams, Fernando, Dickson, Reiter & Harris. 1989, IJ of Fatigue, V. 11, no. 4, p.233.
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Environmental Effects
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0
5000
10000
15000
20000
25000
1.E+02 1.E+03 1.E+04 1.E+05 1.E+06 1.E+07 1.E+08
# cycles
Str
ess
Leve
ls (p
si)
Dry
Wet
Salt
Sult dry= 30.7 ksiSult wet (water) = 22.9 ksiSult, wet (NaCl) = 20.9 ksi
R = 0.1freq = 10 Hz
run outs
Enviro-mechanical Fatigue of Glass/Vinyl
Ester
F. McBagonluri, K. Garcia, M. Hayes, N. Verghese, & J. J. Lesko, "Characterization of Fatigue and Combined Environment on Durability Performance of Glass/Vinyl Ester Composite for Infrastructure Applications" International Journal of Fatigue, Vol. 22, Issue 1, 2000, pp. 53-64.
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Temperature Effects - S-N
Curves
• Branco, Ferreira, Fael & Richardson 1995 Int. J. Fatigue, V. 18, No. 4, p. 255
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Effect of Temperature Effect on E-Glass FRP Fatigue
0
10
20
30
40
50
60
70
80
90
100
100 1,000 10,000 100,000 1,000,000 10,000,000
# cycles
% U
ltim
ate
Te
ns
ile S
tre
ng
th
0
5000
10000
15000
20000
Ma
x s
tre
ss
(p
si)
Sult = 20.9 ksi
R = 0.1freq = 10 Hz
65 °C30 °C
4 °C
Pultruded E-Glass/Vinyl Ester
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So Where Are the Gaps?
•Combined Conditions•Creep & Fatigue
•Temperature & Fatigue
•Temp, Moisture & Fatigue
•Chemistry & Fatigue
•Spectrum loadings (stress and environment)
•Tools•Generalization of Glass Fatigue
•Remaining strength representations for combined loading
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Estimating Remaining Strength
Life
Str
ess
or
Str
eng
th
NStress on Critical Element
Remaining Strength
Initia
l Stre
ngth
•Cycle dependent damage
•Kinetic
•Chemical
•Thermodynamic
Degradation Processes
GeometryConstitutive
Reifsnider & Stinchcomb, “A Critical Element Model of the Residual Strength and Life of Fatigue-loaded Composite Coupons,” ASTM STP 907, 1986
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AMERICAN SOCIETY FOR COMPOSITES
16th Annual Technical Conference
CALL FOR PAPERS
September 9-12, 2001 Virginia Tech, Blacksburg, VA Donaldson Brown Hotel & Conference Center
http://www.esm.vt.edu/ASC/
Abstracts should be submitted no later than January 31, 2001.
M.W. Hyer by e-mail as a pdf file to [email protected]
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QUESTIONS
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Ranking of Importance of Data for Fatigue Effects
Application Area SustainedStress
Loading
Pure FatigueLoading
FatigueAnd Temp.
Fatigue &Moisture /
Salt
Fatigue &Creep
A B C A B C A B C A B C A B CInternal ReinforcementRebar 4 4 2 4 4 2 5 5 1 5 5 1 5 5 1External ReinforcementBeams 3 3 1 4 4 3 5 5 1 5 5 1 5 5 1Slabs 3 3 1 4 4 3 5 5 1 5 5 1 5 5 1Columns 4 4 1 4 4 1 5 5 1 5 5 1 5 5 1Seismic RetrofitColumns, piers 3 5 3 4 4 3 3 5 1 3 5 1 3 5 1Shear Walls 3 5 3 3 4 2 3 5 1 3 5 1 3 5 1Deck SystemsConventionalbeams/girders
4 4 1 5 5 1 5 5 1 5 5 1 5 5 1
Integral/compositebeams/girders
4 5 1 4 5 1 5 5 1 5 5 1 5 5 1
Structural ElementsWall panels, profiles 3 5 2 5 5 2 5 5 1 5 5 1 5 5 1
Rank 5: Critical, cannot go forward without it 3: Important 1: Good to have
Key: A composite B composite/substrate interface; adhesive (if any) C substrate
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Ranking of Availability of Data for Fatigue Effects
Key: A composite B composite/substrate interface; adhesive (if any) C substrate
Application Area SustainedStress
Loading (1)
Pure FatigueLoading (2)
FatigueAnd
Temp.(3)
Fatigue &Moisture /
Salt (4)
Fatigue &Creep (5)
A B C A B C A B C A B C A B CInternal ReinforcementRebar 2 4 2 3 4 2 5 5 1 3 5 1 5 5 1External ReinforcementBeams 2 4 2 2 5 3 5 5 1 5 5 1 5 5 1Slabs 2 4 2 1 5 3 5 5 1 5 5 1 5 5 1Columns 3 5 3 3 5 3 5 5 1 5 5 1 5 5 1Seismic RetrofitColumns, piers 3 4 2 3 4 1 5 5 1 5 5 1 5 5 1Shear Walls 3 4 2 2 4 2 5 5 1 5 5 1 5 5 1Deck SystemsConventionalbeams/girders
2 5 2 4 5 5 1 5 5 1 5 5 1
Integral/compositebeams/girders
2 4 2 4 5 5 1 5 5 1 5 5 1
Structural ElementsWall panels, profiles 2 4 3 3 4 3 5 5 1 5 5 1 5 5 1
Rank 1: Widely available and validated3: Sparse and/or questionable5: Not available
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Overall Ranking of Gaps for Fatigue Effects
Rank 2: Widely available and validated6: Sparse and/or questionable10: Not available
Key: A composite B composite/substrate interface; adhesive (if any) C substrate
Application Area SustainedStress
Loading
Pure FatigueLoading
FatigueAnd Temp.
Fatigue &Moisture /
Salt
Fatigue &Creep
A B C A B C A B C A B C A B CInternal ReinforcementRebar 6 8 4 7 8 4 10 10 2 8 10 2 10 10 2External ReinforcementBeams 5 7 3 6 9 6 10 10 2 10 10 2 10 10 2Slabs 5 7 3 5 9 6 10 10 2 10 10 2 10 10 2Columns 7 9 4 7 9 4 10 10 2 10 10 2 10 10 2Seismic RetrofitColumns, piers 6 9 5 7 8 4 8 10 2 8 10 2 8 10 2Shear Walls 6 9 5 5 8 4 8 10 2 8 10 2 8 10 2Deck SystemsConventionalbeams/girders
6 9 9 9 10 10 2 10 10 2 10 10 2
Integral/compositebeams/girders
6 9 6 9 10 10 2 10 10 2 10 10 2
Structural ElementsWall panels, profiles 5 9 5 8 9 5 10 10 2 10 10 2 10 10 2
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MRLife Methodology1
“n”FatigueCycles
Damage Accumulation Increase in n) CLT
)(
)( Fa
0
00 qsX
n
T
)(
)(
0
00 qsXt
nXtFr
N
nJ
N
nd
N
nJnFaFrnFr
0
1000 )()()(1)0()(
Fa0°
Fr0°1
n2n1
Fa0°
1
N1N2
Off-AxisStiffness
Reductionn/N
Quasi-staticStrength & Stiffness
S-N
0° Critical 90° Subcritical
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Fiber Effects
0
0.2
0.4
0.6
0.8
1
1.E-01 1.E+01 1.E+03 1.E+05 1.E+07
Fatigue Cycles (N)
No
rma
lize
d T
en
sil
e F
ati
gu
e
Str
es
s
High Mod. Graphite
Low Mod. GraphiteKevlar
Uni- E-Glass181 Woven E-Glass
Mandell, J. F. 1982
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• Jones, Dickson, Adam, Reiter, Harris 1983, Composites, V. 14, No.3, July
Material Effects - Kevlar Fibers - (0/90°)
KFRP
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• Jones, Dickson, Adam, Reiter, Harris 1983, Composites, V. 14, No.3, July
Material Effects - E-Glass Fibers - (0/90°)
GRP
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•Gathercole, Reiter,Adam, Harris 1994, IJ of Fatigue, v. 16, no. 8, p.523.
Material Effects - Carbon Fibers - (0/90°)
CFRP
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Tensile Fatigue Damage Mechanism
• Kim & Ebert 1978, J. of Composite Matl., V. 12, April .
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Manufacturing Effects
•S-N curves are dependent upon manufacturing process( P-pultrusion, FW-Filament Winding, PMC-Press Molding of Prepreg)
•Variations in resin and fiber sizing. Curve fit to
o & log(N10)o process related10max logNBA
BNAoo 10log
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Sizing & Matrix Toughening Effects
•Salvia, Fiore, Fournier & Vincent I.J. of Fatigue, 1997,V.19 No.3, p. 253.
BNA
NBA
oo
10
10max
log
log
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Sizing Effects•EP - Epoxy Sizing
•MP - Multi-pupose sizing
•Epoxy Resin
• Salvia, Fiore, Fournier & Vincent I.J. of Fatigue, 1997,V.19 No.3, p. 253.
10max logNBA
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Process Effects
•FW - Filament Winding
•PMC - Prepreg Press Molding
•P - Pultrusion
• Salvia, Fiore, Fournier
& Vincent I.J. of Fatigue, 1997,V.19 No.3, p. 253.
BNAoo 10log
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Sizing & Matrix Toughening Effects
•Salvia, Fiore, Fournier & Vincent I.J. of Fatigue, 1997,V.19 No.3, p. 253.
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Summary from Salvia et al.
•Pultrusion yields lower durabilility composites than Filament wound or press molded
•Resin and sizing strongly affect both A and B of
o was directly related to accoustic emission threshold. o(pultrusion) = 0.0
10max logNBA
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Tensile Strain Fatigue
•Harris 1977 Composites Oct. p. 214.
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Tensile Stress Fatigue
•Harris 1977 Composites Oct. p. 214.
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Material Effects - Shear Fatigue - Mean Stress
•Bevan 1977 Composites Oct. p. 277.
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Fatigue Failure Mechanims - Fatigue Stiffness Loss/Crack Development
• Jamison etc. 1984 ASTM STP 836 p38
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Fatigue - Failure Mechanisms
• Konur & Matthews 1989, Composites, V.20, No. 4, July 1989.
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Fatigue - Fiber Type
• Konur & Matthews 1989, Composites, V.20, No. 4, July 1989.
E-glass Type I Carbon
Type II Carbon
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Fatigue - Fiber Type
• Konur & Matthews 1989, Composites, V.20, No. 4, July 1989.
Type III Carbon
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Environmental Effects-Frequency
• Mandell & Meier 1983 ASTM STP 813 p.60
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Environmental Effects- Dynamic Fatigue
• Mandell & McGarry 1985 Polymer Composites Vol. 6 No. 3 p.168
Single Fiber - NoFiber Interaction
Fiber Bundle
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Environmental Effects- R ratio
• Mandell & Meier 1983 ASTM STP 813 p.60
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Environmental Effects-Temperature
• Ma, Lin, Tai, Wu & Wu 1995, Polymer Composites, V.16, No.3, June.
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Environmental Effects-Hygrothermal Aging
Pooled Fatigue data
• Ma, Lin, Tai, Wu & Wu 1995, Polymer Composites, V.16, No.3, June.
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Environmental Effects R - ratio
• Adams, Fernando, Dickson, Reiter & Harris. 1989, IJ of Fatigue, V. 11, no. 4, p.233.
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Environmental Effects R - ratio
• Adams, Fernando, Dickson, Reiter & Harris. 1989, IJ of Fatigue, V. 11, no. 4, p.233.
)]101ln(1/[)/1(1
/
/
/
)])(1/[(
logNBAo
tc
tm
ta
fe
ef
c
m
a
mcmaf
where
e = endurance value of “f” at high Nfo = f value at low NA and B are curve fit constants needed for the wider range of R curves
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Environmental Effects R - ratio
• Adams, Fernando, Dickson, Reiter & Harris. 1989, IJ of Fatigue, V. 11, no. 4, p.233.
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Environmental Effects R - ratio
• Adams, Fernando, Dickson, Reiter & Harris. 1989, IJ of Fatigue, V. 11, no. 4, p.233.
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• Gathercole, Reiter,Adam, Harris 1994, IJ of Fatigue, v. 16, no. 8, p.523.
Environmental Effects R - ratio
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• Gathercole, Reiter,Adam, Harris 1994, IJ of Fatigue, v. 16, no. 8, p.523.
Environmental Effects R - ratio
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Environmental Effects R - ratio
• Schutz & Gerjarz 1977, Composites Oct. p. 245
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• Schutz & Gerjarz 1977, Composites Oct. p. 245
Environmental Effects R - ratio
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• Highsmith & Reifsnider 1982, ASTM STP 775, p105.
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FIBERS - Tensile Strain Fatigue
• Dharan 1975, J of Matl. Science, V.10, p. 1665.
Graphite
Matrix
E-glass
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• Highsmith & Reifsnider 1982, ASTM STP 775, p105.
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• Highsmith & Reifsnider 1982, ASTM STP 775, p105.
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• Gathercole, Reiter,Adam, Harris 1994, IJ of Fatigue, v. 16, no. 8, p.523.
FIBERS - Shear Stress Fatigue (±45°) Fibers
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FIBERS - Torsional Shear Strain Fatigue - Fiber/Resin
• Phillips & Scott 1977 Composites Oct. p. 233.
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Material Effects - Sizing
• Shih & Ebert, 1987, Comp. Sci. & Tech., V.28, p.137.
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Material Effects - Sizing
• Shih & Ebert, 1987, Comp. Sci. & Tech., V.28, p.137.
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Sizing & Matrix Toughening Effects
• Salvia, Fiore, Fournier & Vincent I.J. of Fatigue, 1997,V.19 No.3, p. 253.
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Process & Laminate Effects - Extracted Uni from Pultruded CP & QI Laminates vs. Uni
0
0.2
0.4
0.6
0.8
1
1.E+03 1.E+04 1.E+05 1.E+06 1.E+07
Fatigue Cycles (N)
No
rmal
ized
Un
i- T
ensi
le
Fat
igu
e S
tres
s
CP2 CP1
QI1 QI2
QI2 at 45° Owen/Corn.
Demers Mandell
• Phifer 1998, Thesis Virginia Tech. http://scholar.lib.vt.edu/theses/available/etd-013199-185939
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FIBERS - Tensile Stress Fatigue
• Dharan 1975, J of Matl. Science, V.10, p. 1665.
E-glass Graphite
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• Adams, Dickson, etc. 1989, IJ of Fatigue, v. 11, no. 4, p.233.
Test Effects: R - ratio