Influence of intra-ply discontinuities on the mechanical behavior of continuous E-glass fiber reinforced composites

Abstract

This study examines how structural discontinuities created during production affect glass fiber-reinforced composite plates. Due to geometrical constraints, the composite microstructure's discontinuities can be categorized as inter-ply and intra-ply. Material testing was conducted at the coupon level as an initial step to ascertain material characteristics. Two full-scale models of intra-ply composite samples were manufactured by employing layers of glass fiber-reinforced prepregs. Discontinuities were generated in the samples using a computer numeric control cutter and then manually applied. The discontinuities' impact on the composite laminate's mechanical properties was assessed through full-scale pieces using three-point bending quasi-static tests. Servo-hydraulic actuators were used to conduct tests on the items. The experimental test results were compared with CAE analysis predictions by evaluating sectional fiber volume fraction. The characteristics of local discontinuities were analyzed using a microscope to enhance the findings of the CAE model. This comprehensive approach offers insights into the intricate connection between internal structural inconsistencies and the mechanical properties of continuous glass fiber-reinforced materials. It supports optimizing composite manufacturing processes and improves composite parts' structural reliability. Dislocation areas were found to result in the formation of resin-rich zones in this investigation. The exothermic curing process in the component's zones results in elevated temperatures, leading to a color change in the resin from clear to yellow. The yellow areas are easily recognizable and show decreased mechanical durability.