This thesis addresses the influence of veil architecture on interlaminar fracture toughness (IFT) of interleaved unidirectional (UD) carbon fibre-epoxy composites with the aim to provide insights. Two nonwoven veils sets formed from polyphenylene sulfide (PPS) fibres with different diameters, with a range of increasing areal density, and a sample of polyetheretherketone (PEEK) fibres, with comparable fibre diameter, are characterised gravimetrically and by tensile tests (long and zero span). Consequently, the anisotropy and maximum stress transfer efficiency (MSTE) parameters are shown by these veils. Subsequently, the veils are interleaved within UD composites and assessed for mode I and mode II IFT. In both modes the veils show a strong dependence on areal density before a plateau at high areal densities, although the lower diameter fibres showed higher IFT values. Interpretation of the results reveal that the difference is attributable to the coverage of veils and thus, to the fraction of fibres in the propagation of crack. However, the effect of fibres is quite evident through the fibre bridging mechanism in the propagation of cracks, more significantly in mode I than in mode II. Moreover, in mode I and mode II a linkage of MSTE of veils with low data variability in IFT is observed. With regard to the anisotropy, this is notably significant only for the PEEK sample, though a statistical analysis supports that the IFT values from both types of fibres are consistent. A comparison of data revealed a slight dependence of the ratio mode II/mode I on areal density only for the larger diameter PPS fibre and the anisotropy of PEEK sample has a strong influence on this ratio. In both modes, however, data presented by this study are consistent with data provided by previous work. Subsequently, mass distribution of veil handsheets is assessed for both modes of IFT into UD composites, revealing no significant dependence of mass distribution on mode I IFT, whereas for mode II this dependence is significant due to the effect a variety of fractional open area size and the floculatted fibres. Fractographic observations via SEM (Scanning Electro Microscope) from representative interleaved composites are analysed and discussed.

The mechanical characterization of the interfacial shear strength (IFSS) of carbon nanotube (CNT) coated carbon fibers and the interlaminar fracture toughness of woven fabric carbon fiber/epoxy composites toughened with CNT/epoxy interleave films is presented. The deposition of multiwalled carbon nanotubes (MWCNT) onto the surface of carbon fibers through thermal chemical vapor deposition (CVD) was used in an effort to produce a graded, multifunctional interphase region used to improve the interfacial strength between the matrix and the reinforcing fiber. Characterization of the IFSS was performed using the single-fiber fragmentation test. It is shown that the application of a MWCNT coating improves the interfacial shear strength between the coated fiber and matrix when compared with uncoated fibers. The effect of CNT/epoxy thin interleave films on the Mode I interlaminar fracture toughness of woven fabric carbon/epoxy composites is examined using the double-cantilever beam (DCB) test. Initiation fracture toughness, represented by critical strain energy release rate (GIC), is shown to improve over standard un-toughened composites using amine-functionalized CNT/epoxy thin films. Propagation fracture toughness is shown to remain unaffected using amine-functionalized CNT/epoxy thin films with respect to standard un-toughened composites.

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This thesis is focused on the development of multiple experimental frameworks to characterize the material properties of composite materials for the LS-DYNA MAT213 model. The main objective is to characterize these properties based on the full-field capture of the evolution of strain and stress fields in coupon-level tests at multiple scales (i.e. macroscopic and microscopic). The experimental work characterized the full-field stress-strain curves and subsequently derived the material properties of T700G/LM-PAEK thermoplastic composites. The data was later successfully utilized to generate the deformation and damage sub-models in the LS-DYNA MAT213 model for the material. Additionally, a three-point bending test methodology was created using a size effect study and geometrically scaled coupons to investigate the Mode-II interlaminar fracture toughness of the material. The experimental frameworks developed herein were also extended to characterize other composite materials, such as those produced via additive manufacturing techniques. Future experimental work will investigate fatigue failure methods for three-point bending in T700G/LM-PAEK. The experimental methods described herein will also continue to support analytical efforts that seek to develop a simulation tool based on the LS-DYNA MAT213 model for modeling the temperature and strain rate-dependent impact damages in composites under multi-axial loading.

Six poly(ether ketone ketone)/carbon composite panels were manufactured from powder coated towpreg. All six panels were initially processed using a hot press equipped with controlled cooling. Four of the panels were used to investigate the effect of cooling rate on crystallinity. A fifth panel was used to investigate the effect of annealing the composite after completion of the standard fabrication process. The sixth panel was used to investigate changes in toughness due to manufacturing towpreg with polymer that had been reclaimed from the towpreg fabrication system’s air cleaner. Cooling rates of 2°C/min, 4°C/min, 6°C/min, and 8°C/min resulted in composites with crystallinities of 33%, 27%, 24%, and 23%, respectively. The principal investigation of the effect of cooling rate on crystallinity and mode I and mode II strain energy release rates, G_Ic and G_IIc, respectively, showed that G_Ic and G_IIc values increase with increasing cooling rate. Comparison of the toughness values as a function of crystallinity showed that the dependence of toughness on crystallinity is approximately equivalent to the dependence of toughness on cooling rate. Comparison of the data from the annealed panel to that from the analogous principal panel showed that annealing increased the crystallinity and decreased the mode I strain energy release rate. There was no effect, however, on the mode II strain energy release rate. Comparison of the data from the panel made with reclaimed polymer to that from its analogous principal panel showed that the reclaimed polymer panel had equivalent crystallinity and G_Ic values. On the other hand, the G_IIc values in this panel were lower than in the analogous principal panel. / Master of Science

Cílem této diplomové práce je lépe porozumět konceptu únavového poškození damage tolerance zmapováním všech možných vlivů na lomovou houževnatost vláknového kompozitu s polymerní matricí. Toho je dosaženo provedením zkoušek za různých podmínek (např. změna parametrů měření, mód zatížení, pořadí vrstev a materiál) a monitorováním odlišností v šíření trhliny. Na základě dat získaných během těchto testů je určena lomová houževnatost. Potenciální rozdíly jsou zkonzultovány a porovnány s ostatními vzorky.