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Characterization of Fatigue Loaded Carbon Fiber

Reinforced Polymer Matrix Composites Using
Infrared Thermography

Conference Paper October 2013

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Characterization of Fatigue Loaded Carbon Fiber Reinforced Polymer

Matrix Composites Using Infrared Thermography

John Montesano
Dept. of Aerospace Engineering, Ryerson University
350 Victoria St., Toronto, ON M5B2K3
CANADA
jmontesano@ryerson.ca

Zouheir Fawaz
Dept. of Aerospace Engineering, Ryerson University
350 Victoria St., Toronto, ON M5B2K3
CANADA
zfawaz@ryerson.ca

Habiba Bougherara
Dept. of Mechanical and Industrial Engineering, Ryerson University
350 Victoria St., Toronto, ON M5B2K3
CANADA
habiba.bougherara@ryerson.ca

ABSTRACT
A study focussed on assessing the fatigue behaviour of braided and woven carbon fiber reinforced polymer
matrix composite materials using infrared thermography is conducted. The intrinsic energy dissipation of
cyclically-loaded braided and woven test specimens is captured by an infrared camera as heat dissipation. The
thermographic methods are satisfactory in tracking the temperature changes associated with critical damage
events, which are correlated with the resulting stiffness degradation behaviour of the materials. Thermography
is also utilized to determine the fatigue strength of the braided and woven test specimens, the results of which
correlate well with the data obtained from a conventional experimental fatigue program. Thermography has
proven to be a viable tool for assessing the fatigue behaviour of fiber reinforced polymer matrix composites.

1.0 INTRODUCTION
Due to the recent employment of advanced polymer matrix composite (PMC) materials for primary load-bearing
aerospace structures, there exists a need to better understand their progressive damage behaviour and the
resulting failure mechanisms during cyclic loading. Carbon fiber reinforced epoxy laminates consisting of
multiple oriented unidirectional layers have been predominantly utilized for these specific applications. Despite
their substantial use, many manufacturing and performance disadvantages have been identified with
unidirectional-ply PMC laminates, which has led to highly conservative component designs [1]. This has

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consequently led to the recent development of fabric-reinforced PMC materials, which include woven, knitted
and braided fabrics among others. Compared to conventional laminates, fabric reinforced PMC components
boast a number of clear advantages [2], [3]. Some of these advantages include having better overall through-the-
thickness strength properties including superior impact damage resistance and delamination resistance, balanced
in-plane performance, improved fatigue performance and lower notch sensitivity. In addition, producing
complex shaped parts can be easier and lower cost due to the conformability of fabrics coupled with an out-of-
autoclave manufacturing process such as resin transfer moulding (RTM). In spite of the indicated advantages,
the use of fabric reinforced PMC materials is only limited to a few applications in the aerospace industry to date.
One of the issues restricting their wider use is that there have been few studies reported in the open literature
which characterize the mechanical behaviour of these PMC materials [4]-[6]. Damage and failure mechanisms
are more complex for fabric PMCs and thus much more difficult to understand, partially due to a number of
fabric geometric variables such as tow size, tow angle and braid/weave pattern. Generally, there is a lack in
available fatigue life and fatigue strength data for these materials, which would otherwise be useful during the
component design stage. Predicting the damage tolerance capabilities of composite structures is essential for
aircraft certification campaigns, while identifying the mechanisms that cause material property degradation
during cyclic loading and defining the fatigue stress-life (S-N) curve are also important design parameters.

A number of non-destructive evaluation (NDE) techniques have been employed in the past with the aim of
characterizing the fatigue behaviour of PMC materials. Some of these NDE techniques include acoustic emission
[7], ultrasonic scanning [8] and x-ray tomography [9]. These methods may not necessarily be practical for in-situ
monitoring due mainly to the limitations of the testing apparatus. Recently, infrared thermography (IRT) has
been established as a means to monitor the performance of composite components [10], [11], providing a non-
contact, in-situ and a real-time assessment of these advanced materials. Thermographic techniques have been
utilized by the authors to assess the development of damage in fabric reinforced PMC materials [12], and to
rapidly determine the high cycle fatigue strength (HCFS) and the entire S-N curve for similar fabric reinforced
PMC plates [13]. In this study, IRT is employed as a non-destructive technique to achieve two main objectives:
(i) determine the critical damage states of cyclically-loaded braided and woven fabric reinforced PMC materials,
and (ii) rapidly define the corresponding S-N curves. The subsequent section outlines the relevant theory for
employing thermographic techniques, while the remaining sections present the experimental details, the results, a
discussion and finally the conclusions.

2.0 INFRARED THERMOGRAPHY BACKGROUND

2.1 General
IRT is a well established non-contact NDE technique for monitoring fatigue damage in structural components.
This is a measurement technique that relies on the use of an infrared (IR) camera to provide a time-dependent
contour map of an objects surface temperature. Thermography involves decoding temperature information which
results from the IR radiation emitted by an object. This can be done actively via external heating or using a
passive heating approach [10]. The passive approach is ideal for cyclic loading because the resulting hysteretic
heating allows for a time-dependent temperature variation which can be monitored with the IR camera. The
recorded images can then be analyzed to determine the material fatigue strength or to understand damage
initiation and development. Analyzing the images can however be a challenge since the detected temperature rise
may be due to a number of different phenomena. For metallic alloys as well as for PMCs the intrinsic energy
dissipation is the main contributor to heat dissipation, and therefore is the best indicator of damage development
[13]. The measured heat dissipation captured by an IR camera will be used in this study to define the critical
damage states of cyclically loaded fabric reinforced PMC plates, and to rapidly determine the HCFS of the same

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components using Risitano's method [14].

2.2 Risitano's Method

This thermographic method was originally developed for metallic alloys and is well documented in the literature
[14]-[16]. The main premise is that for ductile metallic alloys, fatigue failure can occur at stress levels that are
significantly lower than their yield strength. On the microscopic scale metals are neither isotropic nor
homogeneous and can therefore exhibit local fluctuations in stress, which can exceed the material yield limit
causing plastic strains even though the macroscopic stress causes elastic strain. When subjected to repeated
loading, microscopic phenomena (i.e., slip bands and microscopic cracks) can therefore initiate and develop
under these elastic stresses, causing internal dissipation and as a result heat to emanate from the material. It has
been documented that these mechanisms are not prevalent when metals are stressed below their fatigue limit, but
become more prevalent when the fatigue limit is exceeded [14]. In PMC materials subjected to macroscopically
applied elastic stresses, similar local microscopic stress fluctuations can cause intrinsic energy dissipation and
similar heat dissipation. This allows for the use of the thermographic approach to determine the HCFS of
composites.

The main points for proper application of Risitano's thermographic method will now be summarized. The
method assumes that the recorded temperature variation caused by cyclic loading of a test specimen is a measure
of the heat dissipation due to intrinsic energy dissipative mechanisms. The test specimen is cycled for a limited
number of cycles at a given maximum stress level in order to produce stabilization of the surface temperature.
This is repeated for many stress levels at a constant loading frequency, where the schematic of temperature
variation versus cycles for various stress levels is shown in Figure 1(a). As shown, the temperature profiles
follow a three-stage development that correspond to the evolving microscopic damage, which will be discussed
further in Section 4. For each stress level, the corresponding temperature increase from initial to stabilization
(i.e., Tstab during stage II) can be plotted as a function of the applied stress, as shown schematically in Figure
1(b). Then, from the plot it can be seen that when the threshold point is reached the temperature increase is
greater and the fatigue limit can be determined. The hypothesis is that when the fatigue limit is exceeded, the
heat dissipation drastically increases because of the drastic increase in the degree of intrinsic energy dissipation.

Figure 1: Schematic of thermographic methodology for determining HCFS: (a) temperature-cycle

profile, (b) temperature rise-stress profile.

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3.0 MATERIAL AND EXPERIMENTAL DETAIL

3.1 Material
The first material investigated in this study is a thermosetting polyimide resin reinforced with a tri-axially
braided carbon fiber fabric (T650/35-6K) with a 0/60 orientation. The fiber architecture is a regular 2x2 braid
pattern with the 0 or warp yarns ideally non-crimped. The flat braided composite panels were manufactured
using 10 layers of the dry braided fabric and a RTM technique, having final dimensions of 362 mm (warp) by
350 mm. Each panel was cut along the warp direction (i.e., 0 yarn direction) into 12 specimens using an
abrasive waterjet cutting technique. The nominal dimensions of each braided specimen were 355 mm x 25 mm.
The second material investigated is an 8552 epoxy resin reinforced with an 8-harness-satin (8HS) woven carbon
fiber fabric (IM7). The woven fabric yarns each contained 6K fibers, in each the warp and fill directions. The flat
woven composite panels were manufactured using 7 layers of the prepreg SGP 370-8H/8552 material system
from Hexcel using an autoclave, having final dimensions of 355 mm (warp) by 340 mm. Each woven panel was
cut into specimens with dimensions of 250 mm x 25 mm using an abrasive waterjet cutting technique. All test
specimens were equipped with 10 tapered end tabs to eliminate any potential issues with gripping induced
failure. The end tabs were manufactured from 3 mm thick by 25 mm wide 6061-T6 aluminum, and were bonded
to the specimens using Loctite 496 adhesive.

3.2 Experimental Details

All uniaxial tensile tests were conducted at room temperature on an MTS 322 test frame equipped with
hydraulically operated wedge grips. A surface-mounted extensometer was used to monitor the local axial strain
and for calculation of the progressive material stiffness during the cyclic loading tests. A FLIR SC5000 infrared
camera with a pixel resolution of 320 x 240 and a temperature sensitivity of <20 mK was used to monitor the test
coupon surface temperature. A photograph of the test setup with application of the IR camera is shown in Figure
2.

Figure 2: Experimental setup.

Static tests were conducted in displacement control on both braided and woven test specimens in order to obtain

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the respective ultimate tensile stresses, and in accordance with ASTM Standard D3039 [17]. Tension-tension
fatigue tests were conducted in load control with a constant amplitude sinusoidal waveform, a loading frequency
of 10 Hz, and a stress ratio of 0.1 in accordance with ASTM Standard D3479 [18]. Various stress amplitudes
were chosen for the different fatigue tests, and each test was conducted until failure or until a run-off of at least
5M cycles. Additional fatigue tests were conducted in order to apply the thermographic approach for defining
the material HCFS. These tests were also conducted in load control with a loading frequency of 10 Hz and a
stress ratio of 0.1. The test specimen was subjected to a maximum stress amplitude for 10,000 loading cycles,
which was sufficient to produce temperature stabilization. The maximum stress amplitude was increased and the
same test specimen was subjected to another 10,000 cycles; a number of stress levels were chosen and this
process was repeated until the specimen failed.

4.0 RESULTS
This section presents experimental results for both the braided and woven test specimens. In the first sub-section,
the results from using Risitano's method to define the HCFS and the S-N curves for both materials will be
demonstrated. In the second section, temperature profiles captured by the IR camera will be presented and
correlated to stiffness degradation plots for each material.

4.1 HCFS Determination and Fatigue S-N Plots

Fatigue tests were conducted at various maximum stress amplitudes between 50% and 85% of the specimen
ultimate tensile stress (UTS), for each material. The S-N plot defined from a conventional fatigue test program
for the braided material is shown in Figure 3. The data point shown for a maximum stress of 100% UTS and 1
cycle to failure corresponds to the specimen static strength. The plot is linear on the log-scale from the static
strength to the apparent HCFS, which was found to be in the range of approximately 61-64% UTS. All test
specimens cycled with a maximum stress less than the apparent HCFS did not fail after 10M cycles.

* IRT
0.9 Conventional

0.8
max / UTS

0.7
HCFS
0.6
Runoff
0.5

0.4 0 1 2 3 4 5 6 7 8
10 10 10 10 10 10 10 10 10
Cycles to failure (Nf)

Figure 3: S-N curve for braided PMC - conventional fatigue program data points and data points with
HCFS captured using IRT are shown.

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The results from the use of Risitano's method for the braided test specimens to determine the HCFS are shown in
Figure 4 as a temperature rise-maximum stress plot. The characteristic bilinear profile of the extracted data is
clearly shown, which illustrates the significant increase in temperature during cycling once the fatigue strength is
exceeded. The HCFS using the thermographic method was found to be 64% UTS, which corresponds very well
to the data shown in Figure 3. The thermographic technique can further be utilized to determine the entire fatigue
S-N curve. A relationship between the temperature rise and the number of cycles to failure for various maximum
stress levels can be made, which was discussed in detail by Montesano et al. [13]. The Tstab-Nf relationship was
determined for test specimens cyclically loaded at various maximum applied stress levels, which yielded an
integration parameter defined as = Tstab logNf. The integration parameter was constant regardless of the
maximum applied stress. The average value for the integration parameter determined in this study for the braided
material was avg = 51.8 C log(cycle). Therefore, using the average integration parameter and the
corresponding stabilization temperatures found using the IR camera, the number of cycles to failure for various
maximum stress magnitudes were calculated and are included on the S-N curve as asterisks in Figure 3. An
excellent agreement with the experimental data was obtained providing support for the rapid thermographic
approach to determine the entire S-N curve.

Figure 4: Increase in temperature to stabilization vs. maximum stress magnitude for braided
material.

A similar S-N plot defined from a conventional fatigue test program for the woven material is shown in Figure 5,
with an apparent HCFS of approximately 66-69% UTS. All test specimens cycled with a maximum stress less
than the apparent HCFS did not fail after 10M cycles. The results for the same material using Risitano's
thermographic method are shown in Figure 6. The HCFS using the thermographic method was found to be 68%
UTS, which corresponds very well to the data shown in Figure 5. In order to predict the S-N curve using IRT
data, the average value for the integration parameter determined for the woven material was avg = 34.5 C
log(cycle). The corresponding predicted number of cycles to failure for various maximum stress magnitudes are
plotted in Figure 5, which further demonstrates the effectiveness of the thermographic approach.

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* IRT
0.9 Conventional

0.8

max / UTS
0.7 HCFS

0.6
Runoff
0.5

0.4 0 1 2 3 4 5 6 7 8
10 10 10 10 10 10 10 10 10
Cycles to failure (Nf)

Figure 5: S-N curve for woven PMC - conventional fatigue program data points and data points with
HCFS captured using IRT are shown.

10

6
Tstab (C)

2
~68% UTS
1

0
20 30 40 50 60 70 80 90
Maximum Applied Stress (% UTS)

Figure 6: Increase in temperature to stabilization vs. maximum stress magnitude for woven material.

4.2 Temperature and Damage Development

In addition to defining the HCFS and the entire S-N curve, IRT can be utilized to track damage development and
to define critical damage states for PMCs subjected to cyclic loading. The surface temperature of the cycled test
specimens was recorded for the duration of the fatigue tests, until specimen failure. Plots of temperature and
normalized stiffness as functions of the normalized number of loading cycles for one maximum applied stress
level are shown in Figures 7 and 8, respectively, for the braided and woven test specimens. It can be seen that
both materials exhibit a three-stage stiffness degradation profile with rapid initial stiffness degradation, followed
by a constant stiffness degradation rate for the majority of cycling, and finally rapid degradation prior to failure.

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This is characteristic of many PMC materials and can be attributed to a similar three-stage progression of
damage in the form of microscopic cracking [1]. The corresponding temperature profiles illustrated for each
respective material also follow a three-stage development. In fact, during the transition from stage I to stage II of
cyclic loading the levelling-off of the temperature profiles coincide with the transition in the stiffness
degradation plots (i.e., the critical damage state). Similarly during the transition from stage II to stage III of
cycling, the temperature begins to rise dramatically corresponding to the sharp drop in stiffness degradation.
Therefore, temperature tracking using IRT has accurately captured these critical damage states for both the
braided and woven materials.

Figure 7: Braided specimen temperature and stiffness profiles (max = 70% UTS).

Figure 8: Woven specimen temperature and stiffness profiles (max = 80% UTS).

5.0 DISCUSSION
The braided material exhibited a three-stage stiffness degradation during cyclic loading for all maximum applied
stress magnitudes, and is characteristic of many continuous carbon fiber reinforced PMC materials. The rapid
stiffness degradation during the first stage of cycling is attributed to a quick onset and progression of

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microscopic cracking [1]. Crack development reached saturation at the end of this stage in cycling, and for the
majority of cycling was much more gradual. This resulted in the distinct temperature profile shown in Figure 7.
The correlation between the stiffness and temperature profiles proves that the energy (heat) dissipation caused by
microscopic damage development was accurately captured by the IR camera. Similarly for the woven material,
the stiffness degradation also exhibited a three-stage progression. Significant cracking contained within the weft
yarns of the woven fabric composite is characteristic of these materials when subjected to tension-tension cyclic
loading [19], [20]. For the woven specimens, these transverse cracks developed during the early stages of
cycling and were the primary mechanism causing rapid stiffness degradation and the initial temperature rise as
captured by the IR camera.

For both the braided and woven materials, the final temperature rise prior to specimen failure was clearly
captured as shown in Figures 7 and 8. This rise in temperature during the final stage in cycling was
predominantly caused by the initiation and development of the material failure event, which resulted in the final
rapid drop in stiffness. This event consists of a significant development of microscopic damage, which led to the
onset of fiber fracture and ultimately failure of the specimen [1]. This is another critical damage state for both the
braided and woven materials that was accurately captured by thermographic analysis.

Moreover, the thermographic method used to rapidly determine the HCFS for both the braided and woven PMC
materials resulted in accurate predictions, which provides support for this thermographic technique. Each
material demonstrated that once the HCFS was exceeded, the temperature rise was significantly greater which is
attributed to an advanced damage state. At maximum applied stress magnitudes less than the HCFS, the
development of microscopic damage did not advance to a critical state and therefore resulted in a limited
temperature rise. In contrast at maximum applied stress magnitudes greater than the HCFS, damage development
was much more severe resulting in a higher temperature rise. The ability of the IR camera to capture the increase
in the energy (heat) dissipation caused by this advanced damage state and accurately predict the HCFS for both
fabric reinforced PMC materials was shown.

Furthermore, the results illustrated that the entire S-N curve was accurately predicted using thermography. A
relationship between the temperature rise and the number of cycles to failure for different maximum applied
stresses was established. This behaviour is somewhat intuitive since a higher applied stress will result in
advanced damage development, and therefore a greater temperature rise, which leads to a shorter fatigue life.
This led to the definition of a distinct integration parameter for each material, which is effectively a measure of
the area under the temperature rise cycle curve, i.e., T-log(n) curve [13]. Although not the focus of this study, it
should be noted that many unidirectional-ply laminates also exhibit a three-stage stiffness degradation response
during cyclic loading, which is a result of the local crack evolution. Therefore, the application of the
thermographic techniques employed in this study would have to be tested on these laminates to ensure
applicability.

6.0 CONCLUSIONS
Infrared thermography was employed as a non-destructive technique to characterize the fatigue behaviour of
braided and woven carbon fiber reinforced polymer matrix composite materials. Temperature profiles of the test
specimens captured with the infrared camera during tensile cyclic loading correlated very well with the stiffness
degradation profiles for both materials. The resulting critical fatigue damage states for the braided and woven
specimens were accurately captured using thermography, and is attributed to the ability of the thermographic
technique to capture the intrinsic energy dissipation of the materials, which is caused by microscopic damage
development. This technique may be beneficial for assessing the damage tolerance capabilities of polymer

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matrix composites. The ability of the thermographic method to determine the braided and woven material high
cycle fatigue strength, and entire S-N curve, was also demonstrated in this study. The direct benefit is that fewer
test specimens, and significantly less time, is required to define the fatigue S-N data. This may be beneficial for
certification campaigns since using less material and conducting fewer tests will drastically reduce the associated
costs. The experimental results for the braided and woven PMC materials illustrate that infrared thermography is
a practical tool for characterizing the fatigue behaviour of advanced fiber reinforced polymer matrix composite
materials. Although additional testing is required to further validate the usefulness of thermography for
predicting the onset of critical damage states and for defining material S-N data, the obtained results provide
further support for infrared thermography as a viable non-destructive evaluation tool. In addition, alternate
thermographic techniques may be utilized for in-service inspection of components manufactured from these
materials; this is however beyond the scope of this study.

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