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Micro-structure analysis and preliminary failure assessment of braided textile

composites
Prakash Prashanth1, Chong Bing Shen2, Chen Zhong3, Sunil Chandrakant Joshi3, Elvin Ser Ming Chia4
1
Anglo-Chinese School (Independent), 119 Dover Road, Singapore 139656
2
River Valley High School, 6 Boon Lay Avenue, Singapore 649961
3
Nanyang Technological University, 50 Nanyang Avenue, Singapore 639798
4
DSO National Laboratories, 20 Science Park Drive, Singapore 118230

Abstract
Braided textile composites are relatively new in the area of composites. They are known mainly
for their toughness and high shear resistance. They consist of a polymer matrix along with
reinforcement in the form of braided textiles. This report analyzes the tensile properties of
braided textile composites. Composites used for this research were fabricated using Vacuum
Assisted Resin Infusion (VARI) method which resulted in an uneven thickness. Hence, an
attempt has been made to predict the failure region by analysing the cross-sectional area of the
sample. It also discusses the micro-structure of the composite by observing the cross-section
using a microscope. The optical image revealed that the shape of the yarn cross-section varies in
different locations within the composite, from lenticular to elliptical. This will be useful for
researchers trying to model unit cells of braided textile composites via computational means. A
proper analysis of shapes would allow them to perform more accurate finite element analysis.
Introduction
Composites are the combination of a matrix and reinforcement at the macro level. Braiding is the
process of intertwining strands of yarns. These yarns are made up of fibers of various materials
like glass, carbon, Kevlar etc. The textiles after braiding form the reinforcement of the composite
which usually has a polymer matrix. These composites have desirable properties in a particular
direction which is usually unachievable with either of the components alone. One of the
objectives of this research is to study how the yarn shape differs in various layers of the
composite. This will allow researchers to make more accurate models of braided textile
composites. The fabrication process and the tensile properties have also been investigated.

Materials and Methods


Table 1: Specifications of the fabric used in the fabrication of composites (E-glass, Braided
Fiberglass Biaxial Sleevings) [1]
Product Code
Light Fabrics
ZM26L1200R

Diameter
mm
304.8

Angle

45

Yield
m/kg
3.2

Fabric Weight
g/m
325

Thickness at 50% FV
mm
0.25

Fabrication of composites using wet lay-up


The workplace is cleaned thoroughly with acetone to minimise contamination. Next, the area
required is being marked out with double-sided tape. A sheet of plastic cover is placed within the
marked area and secured using tape. This ensures that the composite would not form bonds with
the table. Epoxy resin is prepared by mixing resin and hardener in the weight ratio of 100:34.
The mixture is stirred until it becomes transparent. Then, the braided textile samples are placed
within the marked area and epoxy is poured over them. The epoxy is spread evenly over the

samples. A sheet of peel ply is placed over the samples to ensure that the composites do not bond
with the layer of breather cloth that would be placed over the peel ply. Another sheet of plastic
cover is placed over the entire marked area to ensure that the set-up is air tight. The vacuum is
attached by making a small incision in the upper plastic cover. The vacuum set-up aims to
remove air bubbles from the set-up. The set-up was left to cure for 24 hours. Below is the picture
of the final set-up (Figure 1)

Figure 1: Wet layup setup


The procedures of VARI are similar to that mentioned above. The only difference is that epoxy
resin is injected into the set-up via a tube.
Preparation of samples according to ASTM D3039/ D3039M-00 [2]
The samples had to be furnished to the correct specifications according the American Society for
Testing and Materials (ASTM). The dimensions for a rectangular tensile test specimen are 25mm
by 250mm. The sizes are measured and marked out on the fabricated sample using a marker.
Then, a band saw was used to cut out the specimens.
Cold mounting
The composites were first cut into small 2 cm by 1 cm samples using a band saw. Next, the cut
samples were placed in a mounting cup. 2 parts of Struers ClaroCit Powder and 1 part of Buehler
Simple-Kwick Liquid were thoroughly mixed and poured into the mounting cup. The above
setup was then left to cure for 24 hours inside a fume hood.
Observation of cross section under microscope
The observation surface of the embedded sample was ground and polished using an Ecomet 3
variable speed grinder-polisher and Buehler Metuserv Grinder-Polisher respectively. Samples
were then examined using Olympus BX51 microscope with Sony ExwaveHAD colour video
camera (Model No. SSC_DC58AP). Digital photos were taken using IMAPS Image Capture
Version 3.0 software
Tensile testing of composites
An Instron Universal Testing Machine and Bluehill 3.0 version software were used to capture the
data. The extension speed used during the tensile testing was 1mm per minute initially and later
increased to 2 mm per minute.
The samples that were tested, fail to break in the central region, which is ideal for a tensile test.
Hence an investigation was conducted to find out the reason and region where the composite
fails.

Fracture region prediction


To predict the fracture region of the composite specimen, it was divided into different regions
and was numbered as shown in Figure 2. The shaded areas are predicted failure regions.

Figure 2: Predicted failure regions of a specimen

Cross-sectional Area
(/mm2)

Thickness and width of each individual region were measured using a digital micrometer screw
gauge and digital vernier calipers respectively. These dimensions were tabulated using Microsoft
Office Excel and the average cross-sectional area of each region calculated. The area was then
plotted against the regions so that one can determine the weakest region of the specimen easily.

33
32
31
30
29
28
27
26
25
0 1 2 3 4 5 6 7 8 9 1011121314151617
Region

Figure 3: Cross sectional area-region graph

Figure 4: Specimen under stress

As shown from Figure 3, region 9 has the smallest cross-sectional area. Since the cross-sectional
area of surrounding regions are also rather small, region 6 to 9 were predicted to be the weakest
regions of the specimen. When the specimen was under stress, it would turn opaque as cracks
form. This is shown in Figure 4.

C
B
D
A

Figure 5: Stress-strain graph obtained from experiment

Figure 6: Stress-strain graph

Figure 5 is the actual graph obtained from the experiment. It is a typical load-tensile extension
curve, while Figure 6 is the general stress-strain curve. Both curves have generally the same
shape, except for the initial horizontal line for the experimental curve (Figure 5). That line
signals that slipping of the specimen has occurred as little or no force is required to bring about
elongation of the sample. As Young Moduluss is the ratio of stress to strain at the linear elastic
stage [3], it is the slope of the stress-strain graph in the region (origin to point A in Figure 6)
where the stress is proportional to the strain. However, as Figure 5 is not exactly a stress-strain
curve, it cannot be calculated by just finding the gradient of the initial linear slope. Instead, the
gradient obtained should be multiplied by (where L0 is the initial length of the specimen and
A0 is the original cross-sectional area) in order to obtain the value of Youngs Modulus.
From the above graph we can find out the Youngs Modulus of the composite.

Below are the tabulated results for all our samples. Sample A and C were tested along the axial
direction and sample B and D along the transverse direction.
Table 2: Summary of the results of different samples that were tested
Sample

A
B
C
D

Avg. cross-sectional
area at failure
region/mm2
27.62
32.66
24.99
40.43

Slope of load vs.


tensile extension
graph/(MN/m)
2.5
2.0
2.0
2.5

Initial
length/mm

Young's
Modulus/GPa

16
14
14
14

14.48
8.57
11.2
8.66

Percentage
Elongation at
rupture point
6.38
7.71
6.36
7.36

Shown in Figure 7 below is the stitched photograph of the axial cross-section of the composite
taken using the microscope.

Figure 7: Axial cross-section of composites under microscope


The shape of the yarn is not consistent throughout the sample. The top surface of the photograph
was the side facing downwards during the fabrication process and is hence relatively straight. It
is also visible that the yarns seem more compact and lenticular in shape in the top and the
bottom, while towards the centre of the sample the yarns are more elliptical in shape. The
possible reason can be the relatively higher compaction and resin movement in the surface region
under vacuum than deep inside the lay-up. This is an important observation from the simulations
point of view. Depending upon the magnitude, the method of application and the possible
distribution of the applied pressure on the lay-up while curing shall be taken into account while
choosing a right cross-section for accurately simulating braided composites.
Discussion
The Youngs modulus obtained from the calculation above is a little more than 14 GPa. This can
be attributed to a few main reasons. First, by looking at the cross-section of the sample under a
microscope, it is evident that the fiber volume fraction of the sample is quite low. Second, the
composite is not uniform this might be due to the fabrication procedure where it is difficult to
control the thickness of the composite. Third, as mentioned previously, the initial portion of the
graph appears to be a horizontal line. This indicates that the sample is slipping as there is almost
no load required to bring about an extension and lastly because the sample was not uniform the
stress concentrations at the ends may have affected the results. Better results could probably be
achieved if an extensometer or strain gauge is used to measure the strain in the sample. Those
values can then be used to calculate the Youngs modulus. However, due to resource and
technical constraints, it is not possible to carry out during the project duration.
Since the samples were made using VARI process, it is almost impossible to ensure that the
thickness of the samples are uniform. Hence, there is a difference of about 0.2 to 0.4 mm in the
thickness of a sample. Therefore, failure tends to occur at the region with maximum stress, which
is also the region with minimum cross-sectional area. Thickness and width of the samples are
measured to predict the zones where there would be maximum stress.
The fibers in the composites were being pulled when the specimens are cut using a band saw.
This method of cutting damages the composites; hence a future improvement might be to use a
diamond blade to cut out the samples, since it can cut the fibers more thorough and cleaner
without pulling them.
As seen in Figure 9, the failure is not transverse in nature. The rupture is oblique this is because
of the direction of the yarns which causes some intrinsic shear. This is the reason the composite
fails at an angle.

Figure 8: Specimens after failure

Figure 9: Close-up of the rupture region

In conclusion, the VARI and wet layup methods of fabrication are quick and easy to carry out
but it may not offer a very uniform finish as it is very hard to control the thickness of the sample
through these methods. An alternative would be Resin Transfer Molding (RTM) which makes
use of a mold enabling us to achieve a more uniform finish. Also the shape of the yarn changes
from the outer surfaces to the centre. A proper and more in-depth study into this would make
modeling composites more accurate. The more accurate value of the Youngs modulus can be
calculated using an extensometer or strain gauges to measure the strain.
Acknowledgements
We would like to sincerely thank Aditya Mahesh Khatri and Ji Xianbai from Temasek
Laboratories @NTU for their unwavering support, guidance and encouragement. We would also
like to thank Mr. Lim Yong Seng from the Aerospace Structures Laboratory, MAE, NTU
References
1
A&P Technology Inc. , SharxTM Braided Biaxial Sleevings, Retrieved December 30, 2010 from
http://www.braider.com/?a=57&b=sharx-braided-biaxial-sleevings
2
Wei Mengyao, Test Methods of Composites, Nanyang Technological University, 2010
3
Callister W.D., 2000, Materials Science and Engineering An Introduction, 5th Edition, John
Wiley and Sons, Inc., New York

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