Composite Structure Engineering

Safety Awareness Course

Composite Materials Test Methods

Dr. Dan Adams
Director, Composite Mechanics Laboratory
University of Utah
Salt Lake City, UT 84112
(801) 585-9807 [email protected]

September 14-16, 2010

Composite Materials Test Methods
AGENDA
Constituent and Prepreg Test Methods
Physical Test Methods for Composites
Mechanical Test Methods for Composites
Adhesives Testing
Test Methods for Sandwich Composites
Non-Destructive Testing
Constituent Test Methods
Fibers: CMH-17 Vol. 1, Chapter 3

Physical testing – Density, Thermal Properties

Mechanical testing –Tension

Matrix: CMH-17 Vol. 1, Chapter 4

Thermal/Physical testing – Density, Electrical
Resistivity, Coefficient of Thermal Expansion

Mechanical testing –Tension, Compression,
Shear
Fiber Characterization Testing :
Examples
Physical Testing: For constituent content
(CMH-17 Vol. 1, Sections 3.3, 3.4)

Fiber diameter

Fiber density – ASTM D 3800, liquid displacement

Mechanical Testing
(CMH-17 Vol. 1, Section 3.5)

Tensile properties

 Single fiber tests ASTM D 3379

 Tow tests ASTM D 4018
Matrix Characterization Testing:
Examples
Thermal Analysis (CMH-17 Vol. 1, Section 4.5)

Glass Transition Temperature, Tg

Thermal expansion properties
Physical Testing (CMH-17 Vol. 1, Section 4.5)

Matrix density – ASTM D 792 or D 1505
Mechanical Testing (CMH-17 Vol. 1, Section 4.6)

Tensile properties - ASTM D 638

Compression, shear, flexure
Prepreg Test Methods
CMH-17 Vol. 1, Chapter 5
Focus on properties and characteristics of
uncured prepreg

Fiber and resin content
 Resin extraction, ASTM C 613

Resin flow, gel time

Surface tack, drape
Composite Materials Test Methods
AGENDA
Constituent and Prepreg Test Methods
Physical Test Methods for Composites
Mechanical Test Methods for Composites
Adhesives Testing
Test Methods for Sandwich Composites
Non-Destructive Testing
Physical Test Methods for Composites
CMH-17 Vol. 1, Chapter 6
Density - ASTM D 792
Constituent content (fiber, matrix, voids)

Matrix digestion ASTM D 3171

Ignition loss ASTM D 2584

Image analysis
Flammability
Thermal cycling/microcracking
EMI shielding effectiveness
Tg Determination: Thermoset Composites
CMH-17 Vol. 1, Section 6.6.3
Glass Transition Temperature, Tg: A temperature-induced change in
the matrix material from the glassy to the rubbery state during heating…
A change in matrix stiffness of two or three orders of magnitude occurs
during the glass transition”
Dynamic Mechanical Analysis (DMA)
Most common method
Forced oscillation measurement
ThermoMechanical Analysis (TMA)
Measure changes in thermal expansion
Differential Scanning Calorimetry (DSC)
Measure change in heat capacity associated with Tg
Well suited for neat resin specimens, more difficult with composites
Composite Materials Test Methods
AGENDA
Constituent and Prepreg Test Methods
Physical Test Methods for Composites
Mechanical Test Methods for
Composites (CMH-17 Vol. 1, Chapter 6)
Adhesives Testing
Test Methods for Sandwich Composites
Non-Destructive Testing
Unique Aspects of Testing
Composite Materials

Orthotropy: different stiffnesses and

strengths in different directions.
Minimum thickness flat plates for
testing
Properties not always the same in
tension and compression
 Elastic Material Properties

E
G=
(1 + ν)

2
3

Transverse Isotropy: E2 = E3, ν12 = ν13, G12 = G13

Strength Properties of a
Composite Material (Lamina)
• 3 Axial Tensile Strengths
S1+ , S2+ , S3+
• 3 Axial Compressive Strengths
S1- , S2- , S3-
1
• 3 Shear Strengths
S12 , S13 , S23
2
3

Transverse Isotropy: S2 = S3 S12 = S13

Tension Test For Flat Specimens
ASTM D 3039
Straight-sided specimens
0.5 in. wide, ~ 8 in. long
Adhesively bonded tabs
Strain gages (or extensometer) to
measure axial and transverse strain
(for E, ν12)
Requires valid gage section failure
 Tabbing of Composite Tension
Specimens: Design Variables
Tab Material Tab Geometric Design Adhesive Selection
• G10 or G11 • 0.04-0.08 in. thickness • High strength
glass/epoxy circuit • Between 5° and 30° •Thick bondline (0.010
board material taper angle to 0.050 in.)

Tab
Termination Tab Taper
Region Adhesive Angle
Thickness
Tab
Thickness

Gage Section
Tab Region
Tab Length

Reference: Daniel O. Adams and Donald F. Adams, “Tabbing Guide for

Composite Test Specimens,” DOT/FAA/AR-02/106, October 2002.
http://www.tc.faa.gov/its/worldpac/techrpt/ar02-106.pdf
Categories of Compression Testing
Shear loading methods
IITRI compression test (ASTM D 3410)
End loading methods
Modified ASTM D 695

Combined loading methods

 Combined Loading Compression (CLC),
ASTM D 6641
 Common Compression Test Methods

Shear loading End loading Combined loading

ASTM D 3410 Modified ASTM D 695 ASTM D 6641
• 5.5 in. long specimen • 3.18 in. long • 5.5 in. long
• 0.5 in. gage length specimen specimen
• Versatile • 0.188 in. gage length • 0.5 in. gage length
• Heavy and expensive • Separate tests for • Adjustable loading
modulus (untabbed) ratio via bolt torque
and strength
Shear Testing – Flat Composite Plates

In-plane shear testing: 1

Stiffness: G12 Strength: S12
τ12
2
3

Out-of-plane (interlaminar) shear testing

Stiffness: G13, G23 Strength: S13, S23

1 1

2
τ13 2
τ23
3 3
 Common Test Methods:
In-Plane Shear

Iosipescu Shear V-Notched Rail Shear ±45 Tension Shear

ASTM D 5379 ASTM D 7078 ASTM D 3518
• 3 x 0.75 in. specimen • 3 x 2.2 in. specimen • Combined stress
• Edge loaded • Face loaded state (not pure
• Recommended by CMH- shear)
17 • Easy to perform
Common Test Methods:
Out-Of-Plane (Interlaminar) Shear

Short Beam Shear Iosipescu Shear

ASTM D 2344 ASTM D 5379
• Shear strength only • 3 x 2.2 in. specimen
• Combined stress state • Face loaded
• Small specimen • Modulus and strength
• Simple and affordable test
Other Composite Material Test Methods

“Notched” Laminate Testing

CMH-17 Vol. 1, Section 7.4

Bearing Testing
CMH-17 Vol. 1, Section 7.5

Compression After Impact Testing

CMH-17 Vol. 1, Section 7.7

Fracture Mechanics Testing

CMH-17 Vol. 1, Section 6.8.6
“Notched” Laminate Testing
Laminate test, does not yield a material property
“Notch” = hole
Tested in tension or compression with or without a
fastener (“open” or “filled”)
Open-hole tension Filled-hole tension
Open-hole compression Filled-hole compression
Used to provide design values

Mechanically fastened joints

Effects of manufacturing anomalies and small damage areas
Governed by ASTM standards (D 5766, D 6484)
Example Notched Laminate Testing:
Open Hole Compression Testing
ASTM D 6484
• 12" long x 1.5" wide specimen
• 0.25" diameter center hole
• Face supported
• Clamped in hydraulic grips or
end loaded
• Staggered V-shaped joints in
both sides of the fixture
• Guide plates to maintain
alignment.
Bearing Testing
Laminate test
Utilizes specified bolted joint configuration

Single shear
 One bolt
 Two bolt

Double shear
Used to compare materials and provide design values

Not meant to be representative of actual joint designs

Yield and ultimate bearing strength

Governed by ASTM D 5961
Compression Strength After Impact
(CSAI)

ASTM D 7136 - Damage Resistance

ASTM D 7137 – Damage Tolerance
• 4 in. x 6 in. specimen NASA CAI Test
• 5 in. x 10 in.
specimen
Fracture Mechanics Testing
•Determine propagation characteristics
of existing cracks/delaminations
Mode I
•Considers three modes of crack growth
•Mode I – opening or extension
•Mode II – shear
Mode II
•Mode III – tearing or twist

Mode III

τyz
Fracture Mechanics Test Methods
Mode I: ASTM D 5528

Mode II: Currently no ASTM standard

τyz
Fracture Mechanics Test Methods
Mixed Mode (Mode I & II)
Mixed Mode Bending (MMB) Test, ASTM D 6671

Mode I

Mode II

τyz
Composite Materials Test Methods
AGENDA
Constituent and Prepreg Test Methods
Physical Test Methods for Composites
Mechanical Test Methods for Composites
Adhesives Testing (CMH-17 Vol. 1, Section 7.6)
Test Methods for Sandwich Composites
Non-Destructive Testing
Categories of Adhesives Testing
Adhesive characterization testing

Typically tensile and shear testing

Provides adhesive stiffness and strength data
 Ultimate strength, initial tangent modulus
 Stress versus strain curves

Used for design & analysis, comparisons

Bonded joint characterization testing

Representative of actual joint to be used

Typically do not follow standardized test methods
Adhesive Characterization:
Examples of Shear Test Methods

90°°

0.75 in.

Adhesive Test
Section 3.0 in.

ASTM D 5656 ASTM D 5379

Thick Adherend Specimen Iosipescu Shear Specimen

Reference: Nicholas Burst and Daniel O. Adams, “Investigating the Thin-Film Versus
Bulk Material Properties of Structural Adhesives,” DOT/FAA/AR-06/45,
May 2008. http://www.tc.faa.gov/its/worldpac/techrpt/ar0645.pdf
Bonded Joint Characterization Testing
Composite Materials Test Methods
AGENDA
Constituent and Prepreg Test Methods
Physical Test Methods for Composites
Mechanical Test Methods for Composites
Adhesives Testing
Test Methods for Sandwich
Composites (CMH-17 Vol. 1, Section 6.8)
Non-Destructive Testing
Mechanical Test Methods for
Sandwich Composites
Flatwise Tension ASTM C 297

Flatwise Compression ASTM C 365

Sandwich Panel Shear ASTM C 273

Sandwich Panel Flexure ASTM C 393

Climbing Drum Peel ASTM D 1781

Fracture Mechanics Testing

Sandwich Panel Shear Test
ASTM C 273

Tension Loading Compression Loading

Other Sandwich Panel Tests
Applied
Load Piano
Hinge
Delamination

Crack Tip

Plate Support

Mode I Fracture Mechanics:

Climbing Drum Peel Single Cantilever Beam)
ASTM D 1781 (Proposed ASTM standard)
Composite Materials Test Methods
AGENDA
Constituent Test Methods
Prepreg Test Methods
Physical Test Methods for Composites
Mechanical Test Methods for Composites
Adhesives Testing
Test Methods for Sandwich Composites
Non-Destructive Testing
Why Non-Destructive Testing?
Also referred to as Non-Destructive Inspection (NDI) &
Non-Destructive Evaluation (NDE)
Find defects/anomalies that may affect
composite performance:

Inhomogeneities within the materials

Fiber breakage

Resin micro-cracking

Voids and porosity

Delaminations

Cure deficiencies
NDT vs. “Destructive” Testing
Non-Destructive Testing (NDT) locates
potential problem areas
Destructive (mechanical) testing…

Required to define problem extent

Aided and minimized by analysis

Often both destructive testing and analysis
are required
Typical NDT Techniques For Composites

Visual Inspection
Tap Testing
Ultrasonic Methods
X-Ray
Thermography
Shearography
Visual Inspection
Easiest system to use (eye, microscope)
Can visually detect…

Surface damage (ex: abrasions, cuts, dents)

Blisters, bubbles on surface

Porosity, delaminations (inspection of edges)
First line of investigation
Tap Testing
Follow-on to visual inspection
Based on ability to `hear’ sound
differences
Effective in mapping
delamination areas
Used extensively because of
ease and cost
Computer-aided/electronic tap
testers available for commercial
usage http://www.asi-nde.com
Ultrasonic Test Methods
Used to monitor for delaminations,
voids/porosity, fiber/matrix damage

Through-transmission

Requires access to both sides
of composite structure

Pulse echo

Requires access from only one side
of composite structure

More applicable to field inspections
X-Ray Inspection
Detects density changes
Well suited for bonded interfaces
Can locate delaminations, voids,
porosity, moisture, inclusions
Technique in use many years
(rocket motors, nozzles)
Thermography
Uses heat transfer --- not sound waves
Requires infrared video camera
Measures effects from thermal changes
Useful for locating delaminations and
contamination (moisture, solvents)
Potential field usage

Delamination
References:
Composite Materials Test Methods
CMH-17, Composite Materials Handbook, Volume 1
“Experimental Characterization of Advanced Composite
Materials,” by Donald F. Adams, Leif A. Carlsson, and
R. Byron Pipes, CRC Press.
ASTM Annual Book of ASTM Standards, Volume 15.03,
Space Simulation; Aerospace and Aircraft; Composite
Materials
ASTM D 4762, “Standard Guide for Testing Polymer
Matrix Composite Materials”