Test Methods, Standards and 

Certification Requirements

BTG Composites Inc. 2010 1
 Categories of Static Mechanical Property 
Testing

y Tension Testing
y Compression Testing
y Shear Testing
y Flexure Testing
y Miscellaneous Mechanical Tests
y Fracture Mechanics Testing

BTG Composites Inc. 2010 2
 Review of elastic material properties
y E  ≡ Young’s Modulus, Modulus of Elasticity
σ
Initial Slope of stress vs. strain curve E

y ν ≡ Poisson's ratio ε
Ratio of transverse to axial strain
ν = ‐ εy/ εx for an applied σx
σx σx

τ
y G ≡ Shear Modulus, Modulus of Rigidity G
Initial Slope of shear stress vs. shear strain curve γ

For isotropic materials (metals),  E
G=
there are only 2 independent properties 2( 1 + ν )

BTG Composites Inc. 2010 3
 Elastic Properties 
for a Composite Material 
y 3 Elastic moduli 
3
E1, E2, E3 2

y 3 Poisson’s ratios 1
ν12,  ν 13,  ν 23
y 3 Shear moduli
G12, G13, G23

Note that E’s and ν’s may differ for 
tension and compression loading

BTG Composites Inc. 2010 4
 Required Elastic Material Properties 
for Composites
y Metals (isotropic materials)
y E, G, ν 3
E 2
y 2 independent properties: G=
2( 1 + ν ) 1

y Composite lamina (unidirectional layer, ply)
y In plane:  E1, E2, G12, ν12
y Out of plane: E3, G13, G23, ν13, ν23
y But for transverse isotropy (2 = 3):
E2 = E3        G12 = G13 ν12 = ν13   E 33
G 23 =
2( 1 + ν 23)
Therefore 5 independent elastic properties

BTG Composites Inc. 2010 5
 Strength Properties for a Composite 
Material 
y 3 Axial tensile strengths
S1+  ,  S2+ ,  S3+ 
y 3 Axial compressive strengths 3
2
S1‐ ,  S2‐ ,  S3‐
1
y 3 Shear strengths
S12 ,  S13 ,  S23

BTG Composites Inc. 2010 6
 Unique Aspects of Testing 
Composite Materials 

y Orthotropy ‐ different stiffnesses and strengths in 
different directions. 
y Thinness – essentially two‐dimensional on a local 
scale
y Properties not always the same in tension and 
compression

BTG Composites Inc. 2010 7
 Properties to be Determined From 
Tension Testing
3
Tension Testing in 1 (Fiber) Direction 2

y Elastic Properties:  E1T, ν12T 1
y Strength Property:  σ1 ultT
Tension Testing in 2 (Transverse) Direction
y Elastic Properties:  E2T, (ν21T)
y Strength Property:  σ2 ultT
Tension Testing in 3 (Out‐of‐Plane) Direction
y Elastic Properties:  (E3T), (ν31T)
y Strength Property:  (σ3 ultT )

BTG Composites Inc. 2010 8
 Typical Tension Failure …

BTG Composites Inc. 2010 9
 Tension Test For Flat Specimens
ASTM D 3039

y Straight‐sided specimens
y 0.5 in. wide, ~ 8 in. long
y Adhesively bonded tabs
y Strain gages (or extensometer) to 
measure axial and transverse strain 
(for E, ν12)
y Requires valid gage section failure

BTG Composites Inc. 2010 10
 Split Disk Tensile Test
ASTM D 2290
• Hoop-wound rings
• 5.75" inside diameter x 0.25" wide
• Can be strain gauged to provide modulus
• Place strain gages 15-30° from split
line
• Average modulus from tension and
compression loading

Reference: Yoon et al., “Measurement of Modulus in Filament

Wound Ring Specimen Using Split Disk Test,” Experimental
Techniques, Vol. 21, No. 1, Jan/Feb 1997, pp. 25-28.

BTG Composites Inc. 2010 11
 Tabbing of Composite Tension
Specimens: Design Variables
Tab Material Selection Tab Geometric Design Adhesive selection
• Tab material • Tab thickness • Adhesive
strength strength
• Tab length
• Tab material • Adhesive
• Tab taper angle
stiffness stiffness
• Adhesive
Tab
Termination
thickness
Region Tab Taper
Angle
Adhesive
Thickness Tab
Thickness

Gage Section
Tab Region Tab Length

BTG Composites Inc. 2010 12
 Tabbing of Composite Tension
Specimens:
Computational Analyses

py, pxy 1.0550 0.070

u=0 specified 1.0510 0.064
1.0470 0.058
(symmetry)
1.0430 0.052
1.0390 0.046
1.0350 0.040
v = 0 (symmetry) 1.0310 0.034
1.0270
σx 0.028
1.0230
σy 0.022
1.0190
τxy 0.016
1.0150 0.010

0 20 40 60 80 100
Taper Angle (degrees)

BTG Composites Inc. 2010 13
 Recommended Tab Configurations
Tab Material: G-10 or G-11 glass fabric/epoxy laminated circuit
board recommended
• Adequate strength to transmit the required load
• As compliant (low stiffness) as possible.

Tab Thickness: 0.04-0.08 in. ( 1-2 mm) recommended

• 0.062 in. thick G-10 glass fabric/epoxy laminated circuit board is
commonly available

BTG Composites Inc. 2010 14
 Recommended Tab Configurations
(cont)
Tab Length:
2 in. minimum recommended
• Use longest tab length permitted by the test grips

Tab Taper Angle:

Between 10° and 15° recommended
•Minimize tab termination stress concentrations

BTG Composites Inc. 2010 15
 Recommended Tab Configurations
(cont)
Adhesive:
Select a high strength adhesive that is easy to work with
•A lower modulus adhesive is preferred

Adhesive thickness:
A thicker adhesive layer (~0.05 in.) is recommended
•Further reduce tab termination stress concentrations

BTG Composites Inc. 2010 16
 Tab Bonding Procedure
• Determine fiber orientation within panel
• Prepare surfaces of panel and tabs
•Mask gage section of panel
•Grit blasting or sanding
• Attach gage section spacer to panel

• Apply wire bondline spacers

• Apply adhesive to panel and tabs

BTG Composites Inc. 2010 17
 Properties Determined From Compression
Testing
3
Compression Testing in 1 (Fiber) Direction 2

y Elastic Properties:  E1C, ν12C 1
y Strength Property:  S1‐

Compression Testing in 2 (Transverse) Direction
y Elastic Properties:  E2C, (ν21C)
y Strength Property: S2‐

Compression Testing in 3 (Out‐of‐Plane) Direction
y Elastic Properties:  (E3C), (ν31C)
y Strength Property:  (S3‐)

BTG Composites Inc. 2010 18
 Typical Compression Failure …

BTG Composites Inc. 2010 19
 Categories of Compression Testing

Shear loaded methods
y Celanese compression test 
y IITRI compression test
End loaded methods
y Boeing Modified ASTM D 695
y NASA short block compression test
Combined loading methods
y Combined loading compression (CLC)

BTG Composites Inc. 2010 20
 Celanese Compression Test
ASTM D 3410
•Side loaded tabbed specimens
•5.5 in. long, 0.5 in. wide specimen with 0.5
in. gage length
•0.157 ± 0.002 in. thickness of tabbed
region
•Outer alignment sleeve
•Not recommended

BTG Composites Inc. 2010 21
 IITRI Compression Test
ASTM D 3410
• Side loaded tabbed specimens
• 5.5 in. long, 0.5 in. gage length
• 0.5 – 1.5 in. specimen width
• 0.17 – 0.60 tabbed thickness
• Heavy and expensive
• Versatile

BTG Composites Inc. 2010 22
 Modified ASTM D 3410
Compression Test Fixtures

Wyoming Modified Wyoming Modified

Celanese IITRI

IITRI Fixture(to scale)

BTG Composites Inc. 2010 23
 Boeing Modified ASTM D 695
• End loaded, face supported
• I-shaped lateral support
• Straight-sided specimen
– untabbed for modulus measurement
(premature end-crush failure)
– tabbed for compressive strength
(0.2 in. gage section too short for
strain gage)

BTG Composites Inc. 2010 24
 NASA Short Block Compression
Test
• End loaded, end clamped
• Adjustable clamping
pressure
• 2.25” tall x 1.5 in. wide
specimens commonly used
• Well suited for textile
composites

BTG Composites Inc. 2010 25
 Combined Loading Compression
Test ASTM D 6641

• Standardized by ASTM in 2001

• Two pairs of clamped steel blocks
• Combined end load and side load
• 5.5” long, 0.5” gage length (variable)
• Specimen widths to 1.2”
• Adjustable loading ratio via adjustable
bolt torque

BTG Composites Inc. 2010 26
 Recommended Tab Configurations:
Compression Specimens
Tab Material: G-10 or G-11 glass fabric/epoxy laminated circuit
board recommended
• Adequate strength to transmit the required load
• Relatively low stiffness (~ 5 Msi) a good choice.

Tab Thickness: 0.04-0.08 in. ( 1-2 mm) recommended

• 0.062 in. thick G-10 glass fabric/epoxy laminated circuit board is
commonly available

BTG Composites Inc. 2010 27
 Recommended Tab Configurations
for Compression (cont)
Tab Length:
2 in. minimum recommended
• Use longest tab length permitted by the test grips

Tab Taper Angle:

A 30° taper angle recommended for general use
A 90° taper angle may be used with a thick adhesive bondline
•Minimize tab termination stress concentrations
•Prevent specimen buckling

BTG Composites Inc. 2010 28
 Recommended Tab Configurations
for Compression, (cont)
Adhesive:
Select a high strength adhesive that is easy to work with
•A lower modulus adhesive is preferred

Adhesive thickness:
A thicker adhesive layer (~0.05 in.) is recommended if using a 90° tab
taper angle
•Further reduce tab termination stress concentrations

BTG Composites Inc. 2010 29
 Properties to be Determined 
From Shear Testing
Shear Testing in 1‐2 Plane
y Elastic Properties:  G12 3
2
y Strength Property:  S12 
Shear Testing in 1‐3 Plane 1
y Elastic Properties: (G13) 
y Strength Property: (S13)
Shear Testing in 2‐3 Plane
y Elastic Properties: G23
y Strength Property: S23

BTG Composites Inc. 2010 30
 Short Beam Shear Test
ASTM D 2344

•Used to obtain interlaminar (out-of-plane)

shear strength
•Does not provide shear modulus
•Specimen span length-to-thickness ratio
of 4-5
•Typical specimens 0.1" thick, with span
length of 0.4" to 0.5".

BTG Composites Inc. 2010 31
 Iosipescu (V-Notch) Shear Test
ASTM D 5379
•3" long x 0.75" wide specimen
•Opposing 90° V-notches machined
•±45° biaxial gage or a special Iosipescu
gage to measure modulus

BTG Composites Inc. 2010 32
 Two Rail Shear Test
ASTM D 4255
• In-plane shear modulus and shear
strength
•Usable for various laminates
•Large 6" long x 3" wide specimen
with six large holes
•Bolted rails

BTG Composites Inc. 2010 33
 Three Rail Shear Test
ASTM D 4255
• In-plane shear modulus and shear
strength
•Usable for various laminates
•Large 6" long x 5.375" wide
specimen with 9 large holes
•Bolted rails

•Two separate tests

performed at once

BTG Composites Inc. 2010 34
 Attractive Features of
the V-Notched Rail Shear Test
• Incorporates attractive features from existing tests
– Iosipescu shear(ASTM D 5379)
• Favorable stress state
• Gage section failures
V-Notched
– Modified rail shear (ASTM D 4255)
3 in. x 2.2 in.
• Capable of testing high
shear strength laminates
• Moderate sized test specimen
• Provides versatile shear test
– In-plane shear modulus and strength
– Useable for variety of composite laminates Iosipescu
• Modest test costs 3 in. x 0.75
in.

Current Rail
Shear
3 in. x 6 in.

BTG Composites Inc. 2010 35
 3 or 4 Point Flexure
ASTM D 790, D 6272
• Span dependent on material being
tested
• Span to thickness ratios range from
16:1 to 60:1 depending on material
being tested
• Typical dimensions:
• 0.1 in. thick x 4 in. long
• 3.2 in. span length (32:1)
• 4-point bend: third-point or quarter
point loading used

BTG Composites Inc. 2010 36
 Boeing Open Hole Compression
Test
• 12" long x 1.5" wide specimen
• 0.25" diameter center hole
• End-loaded/face supported
• Staggered V-shaped joints in both sides
of the fixture
• Guide plates to maintain alignment.

BTG Composites Inc. 2010 37
 Northrop Open Hole
Compression Test
• 3" long x 1" wide specimen
• 0.25" diameter center hole
• End-loaded/face supported
• Cutouts to accommodate strain gages
and lead wires
• Fixture lightly clamped between outer
restraining plates for alignment

BTG Composites Inc. 2010 38
 Compression After Impact (CAI) Tests

Boeing CAI Test NASA CAI Test

•4” x 6” specimen •5” x 10”
•Simply supported all 4 specimen
edges

BTG Composites Inc. 2010 39
 CLIMBING DRUM PEEL TEST
ASTM D 1781

• Used for sandwich panels

and solid laminates
• Solid laminates: 9.5" x
1.75" steel backing plate
• Measures force required to
peel layer off laminate

BTG Composites Inc. 2010 40
 ROLLER DRUM PEEL TEST FIXTURE
ASTM D 3167

• Greater peel angle than Climbing Drum

Peel test (more severe)
• Uses 0.5 – 1 in. wide x 10+ in. long
laminate
• “Flexible” and “rigid” adherends
• 2" extension of the flexible adherend for
gripping
• Measures force required to peel
adherends

BTG Composites Inc. 2010 41
 Fracture Mechanics Tests
• Determine propagation characteristics of
existing cracks/delaminations

Mode I
• Considers three modes of crack growth
•Mode I – opening or extension
•Mode II – shear
•Mode III – tearing or twist Mode II

Mode III

BTG Composites Inc. 2010 42
 Fracture Mechanics Tests:
Mode I and Mode II
Mode I

Mode II

BTG Composites Inc. 2010 43
 Fracture Mechanics Tests:
Mixed Mode (I and II)
Mixed Mode Bending (MMB) Test

Mode I

Mode
II

BTG Composites Inc. 2010 44
 Typical Industry Safety Factors

BTG Composites Inc. 2010 45
 Commonly Required or Imposed 
Safety Factors for Composites
y Disney amusement rides (8‐10)
y Commercial products w/limited supporting test data (4‐6)
y Amusement rides per ASTM (4‐5)
y Automotive CNG tanks:
y Glass fiber (3.50)
y Aramid fiber (2.25‐3.00)
y Carbon fiber (2.25)

BTG Composites Inc. 2010 46
 Safety Factors (continued)
y Low pressure automotive tanks (5)
y AWWA standard pressure pipe (1.8‐4.0)
y Sports & recreation products (2‐4)
y Commercial and military aircraft (2)
y Rocket motor composite cases:
y Joint areas of reinforcement (2)
y Most other composite areas (1.25‐1.5)

BTG Composites Inc. 2010 47
 Safety Factors (continued)
y Infrastructure applications:
y Static loading (e.g. Column wrapping):
y Glass fiber (4.0)
y Carbon fiber (1.8)
y Continuous loading (e.g. Bridge decks):
y Glass fiber (5.0)
y Carbon fiber (3.33)
y NOTE: Some of these are `typical’ values whiles others are 
dictated by Standards

BTG Composites Inc. 2010 48
 Damage Assessment Testing

BTG Composites Inc. 2010 49
 Wound‐In Teflon 
Delamination
y Wound‐in Teflon 
`delamination’
y 146‐inch diameter 
carbon fiber/epoxy 
pressure vessel
y Assessment of 
delamination 
growth and failure 
level

BTG Composites Inc. 2010 50
 Impact Heads & Events Vary
y Impact head (“tups”) 
shape mirrors field and 
processing events:
y Round
y Hemispherical
y Triangular
y Various diameters
y Line indenter
y Accept‐Reject Criteria

BTG Composites Inc. 2010 51
 Dome Impact on Pressure Vessel

BTG Composites Inc. 2010 52
 Full‐scale Impact Testing
y Full‐scale FW test 
cylinder for pressure 
vessel evaluation
y Internal support
y Vary impact head 
shape
y Vary energy level
y Vary drop angle

BTG Composites Inc. 2010 53
 Open Cylinder Impact Test
y Un‐supported test 
cylinder in drop tower
y Two tests possible:
y No support under 
impactor results in 
flexing
y Rigid support under 
impactor results in 
severe local damage

BTG Composites Inc. 2010 54
 Rigid Cylinder Impact Test
y Rigid end plates
y Simulates reinforced 
pressure vessel regions
y Increases delamination 
damage
y Increase carbon fiber 
damage

BTG Composites Inc. 2010 55
 Pipe Design and Certification 
Testing

BTG Composites Inc. 2010 56
 FRP Pipe Pressure Testing
y FRP pipe 
pressure test:
y Up to 800 mm 
diameter
y Without axial 
loads induced
y 20 bar to 800 
mm
y 80 bar to 300 
mm

BTG Composites Inc. 2010 57
 Large Diameter Pressure Tests
y Very large 
diameter 
pressure testing
y 1200 mm to 15 
bar
y Pressure test 
level inversely
proportional to 
pipe diameter

BTG Composites Inc. 2010 58
 Pressure Tests w/Axial Load
y Bench test to high 
pressures
y Axial load due to 
confined fixture
y Tests to 120 bar
y Short segment 
FRP pipe units

BTG Composites Inc. 2010 59
Constrained Pipe Pressure Tests
y Another short‐
segment FRP pipe 
pressure test
y Wide range of FRP 
pipe diameters
y Standard test 
approach

BTG Composites Inc. 2010 60
 Min/Max Pipe Pressure Levels

BTG Composites Inc. 2010 61
 High Pressure Qual Testing
y High pressure 
FRP pipe test in 
protective cage
y Used in Qual 
Testing  quite 
often
y Detects onset 
of `weeping’ 
pressure

BTG Composites Inc. 2010 62
ASTM FRP Pipe Material Standards

BTG Composites Inc. 2010 63
 Typical FRP Pipe Standards
y AWWA 
y ASTM
y API
y DVN
y BS
y EN
y ISO
y WRc

BTG Composites Inc. 2010 64
 Pipe Stiffness Measurement
y Diametral 
compression tests 
for FRP pipe 
stiffness:
y Hoop stiffness
y Load‐deflection test
y Pipe Stiffness Class 
determination
y Simple test program

BTG Composites Inc. 2010 65
 Pipe Stiffness/Deflection Test

BTG Composites Inc. 2010 66
 Long Term Corrosion Tests
y ASTM long‐term 
deflection tests:
y Corrosion testing
y Various fuels
y Water
y Acids
y Assess affects of 
liquids on long‐
term behavior

BTG Composites Inc. 2010 67
Long Term Acid Exposure Tests

BTG Composites Inc. 2010 68