Current and future potential applications for three-dimensional (3D) fibre reinforced polymer composites made by the textile processes of weaving, braiding, stitching and knitting are reviewed. 3D textile composites have a vast range of properties that are superior to traditional 2D laminates, however to date these properties have not been exploited for many applications. The scientific, technical and economic issues impeding the more widespread use of 3D textile composites are identified. Structures that have been made to demonstrate the possible uses of 3D composites are described, and these include applications in aircraft, marine craft, automobiles, civil infrastructure and medical prosthesis.

Review of applications for advanced three-dimensional fibre textile composites

This paper reviews published research into polymer composite laminates reinforced in the through-thickness direction with z-pins. Research into the manufacture, microstructure, delamination resistance, damage tolerance, joint strength and mechanical properties of z-pinned composites is described. Benefits of reinforcing composites with z-pins are assessed, including improvements to the delamination toughness, impact damage resistance, post-impact damage tolerance and through-thickness properties. Improvements to the failure strength of bonded and bearing joints due to z-pinning are also examined. The paper also reviews research into the adverse effects of z-pins on the in-plane mechanical properties, which includes reduced elastic modulus, strength and fatigue performance. Mechanisms responsible for the reduction to the in-plane properties are discussed, and techniques to minimise the adverse effect of z-pins are described. The benefits and drawbacks of z-pinning on the interlaminar toughness, damage tolerance and in-plane mechanical properties are compared against other common types of through-thickness reinforcement for composites, such as 3D weaving and stitching. Gaps in our understanding and unresolved research problems with z-pinned composites are identified to provide a road map for future research into these materials.

Review of z-pinned composite laminates

This review compiles knowledge about the mechanical and structural performance of brittle matrix composites. The overall philosophy recognizes the need for models that allow efficient interpolation between experimental results, as the constituents and the fibre architecture are varied. This approach is necessary because empirical methods are prohibitively expensive. Moreover, the field is not yet mature, though evolving rapidly. Consequently, an attempt is made to provide a framework into which models could be inserted, and then validated by means of an efficient experimental matrix. The most comprehensive available models and the status of experimental assessments are reviewed. The phenomena given emphasis include: the stress/strain behaviour in tension and shear, the ultimate tensile strength and notch sensitivity, fatigue, stress corrosion and creep.

The physics and mechanics of fibre-reinforced brittle matrix composites

Meso-FE modelling of textile composites: Road map, data flow and algorithms

Improving the delamination resistance of CFRP by stitching—a review

Observations of failure mechanisms in monotonic loading are reported for graphite/epoxy composites containing three-dimensional (3D) interlock weave reinforcement. The key phenomena are delamination and kink band formation in compression, tow rupture and pullout in tension, and combinations of these in bending. The materials exhibit great potential for damage tolerance and notch insensitivity. This is partly due to the presence of geometrical flaws that are broadly distributed in strength and space; and partly to the coarseness of the reinforcing tows, which leads to extensive debonding and reduced stress intensification around sites of failure. Rules of mixture corrected for the effects of tow irregularity suffice to estimate elastic moduli. Rough estimates of the stress at which the first failure events occur in compression or tension can be made from existing micromechanical models. Ultimate tensile failure might be modeled by regarding failed tows that are being pulled out of the composite as a cohesive zone. The characteristic length estimated for this zone, which is a direct measure of damage tolerance and notch insensitivity, has very large values of order of magnitude 0.1–0.5 m.

Failure mechanisms of 3D woven composites in tension, compression, and bending

Tensile tests are reported for some graphite/epoxy composites with three-dimensional woven interlock reinforcement. Composite failure consists of the accumulation of discrete tow rupture events distributed over a band of damage typically 10–20 mm wide. Load—displacement data for gauges spanning the band indicate work of fracture values ranging from 0.4 to 1.1 MJ m −2 . Most of these unusually high vales derives from the ability of the composite to sustain loads near peak load (≈1 GPa) for displacements significantly beyond those at which tows have all failed. The key mechanism is very strong friction or lockup that couples sliding, broken tows to the surrounding composite. Lockup is the product of the geometrical irregularity of nominally straight tows and clamping compressive stresses generated by the through-thickness reinforcement. Lesser contributions to the work of fracture arise from plastic straightening of tows prior to their rupture and the relatively easy but prolonged pull-out of tows following failure of the lockup mechanism.

On the tensile failure of 3D woven composites

The elastic properties of graphite/epoxy composites with three-dimensional interlock weave reinforcement have been measured over length scales somewhat greater than the characteristic length of the weave pattern. Orientation averaging models similar to those developed elsewhere over the last twenty years provide estimates of elastic constants that are in fair agreement with the experimental data. However, in-plane Young's moduli are consistently too high and properties related to the through-thickness reinforcement show considerable scatter. Most of the discrepancies can be attributed to waviness and other geometrical irregularities in nominally straight tow segments. Much improved agreement with in-plane properties is obtained by measuring and accounting for the out-of-plane waviness of in-plane tows. Other observed distortions of in-plane tows and irregularity in through-thickness tows are very difficult to quantify experimentally. There results a significant and apparently unavoidable uncertainty in pr...

The Macroscopic Elasticity of 3D Woven Composites

Investigations of cracking in multilayered ceramic/metal composites are presented. Two aspects are considered: crack renucleation across intact single metal layers and subsequent crack extension. Crack renucleation criteria are determined and compared with predictions. High-resolution strain-mapping techniques are employed to determine the surface strain fields surrounding cracks. Good agreement is found between these experimental measurements and the predictions of a small-scale yielding model. Subsequent crack progression occurs either by the extension of a dominant, nearly planar crack or by the formation of a zone of periodically spaced cracks. Both patterns are analyzed. The dominant cracking behavior is found to depend on the volume fraction and yield strength of the metal.

Cracking and damage mechanisms in ceramic/metal multilayers

The present study of angle-interlock woven polymer matrix composite behavior under uniaxial monotonic compression notes these materials to be macroscopically ductile, with compressive strains in failure that can exceed 15 percent. Some of the tests conducted on stitched laminates indicated brittle behavior. Woven composite failure mechanisms have been studied by a combination of optical microscopy, moire interferometry, stereoscopy, and digital image comparisons; the critical failure event was in all cases a kink band formation in the primary load-bearing axial rows.

Mahyar S. Dadkhah

Papers

Failure mechanisms of 3D woven composites in tension, compression, and bending

On the tensile failure of 3D woven composites

The Macroscopic Elasticity of 3D Woven Composites

Cracking and damage mechanisms in ceramic/metal multilayers

Mechanisms of compressive failure in 3D composites