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Composites: Part A
journal homepage: www.elsevier.com/locate/compositesa
A total fatigue life model for the prediction of the R-ratio effects on fatigue
crack growth of adhesively-bonded pultruded GFRP DCB joints
Moslem Shahverdi, Anastasios P. Vassilopoulos ⇑, Thomas Keller
Composite Construction Laboratory (CCLab), Ecole Polytechnique Fédérale de Lausanne (EPFL), Station 16, Bâtiment BP, CH-1015 Lausanne, Switzerland
a r t i c l e i n f o a b s t r a c t
Article history: A new phenomenological fatigue crack growth formulation for the modeling and the prediction of the
Received 8 November 2011 Mode I fatigue behavior of adhesively-bonded pultruded glass fiber-reinforced polymer double cantilever
Received in revised form 2 May 2012 beam joints under different R-ratios is introduced. The established formulation is based on the total
Accepted 14 May 2012
fatigue life concept, considering however the model parameters as functions of the R-ratio by fitting
Available online 24 May 2012
the existing experimental data under two to three different R-ratios. This model can subsequently be
used for the derivation of fatigue crack growth curves under any different R-ratio, thus assisting the
Keywords:
development of methodologies for the fatigue life prediction of a joint comprising adherends with the
B. Fatigue
B. Fracture
same material under realistic loading conditions. An extensive fatigue/fracture database has been
C. Analytical modeling derived, containing results of 28 Mode I fatigue experiments, to assist the model development and to val-
E. Pultrusion idate its predictions. Comparison of the model predictions and experimental results proved the model’s
validity.
Ó 2012 Elsevier Ltd. All rights reserved.
1. Introduction is. Strength, stiffness, crack density, and crack length are some of
the damage metrics that have been used in the past. The methods
Today it is widely accepted that fatigue is one of the most com- based on each damage metric present certain advantages and dis-
mon failure mechanisms exhibited by composite materials and advantages, which have been discussed in detail elsewhere, see
structures and it is well documented that the majority of structural [1,3] for example.
failures occur due to a fatigue mechanism [1]. Joints are the most Use of the crack that is initiated and propagated in the material
critical structural elements as they often become the weak links during fatigue loading as the damage metric has been proved very
in engineering structures. Although bolted and bonded joints have valuable for metals, where one crack is created and its propagation
their advantages and disadvantages, adhesively-bonded joints are controls the material’s behavior. However it is questionable
preferred for permanent connections in civil engineering struc- whether the same concept can be used for composite materials,
tures [2]. However, modeling of the behavior of adhesively-bonded in which failure is a result of the interaction of different phenom-
joints in engineering structures subjected to multiple loading spec- ena (matrix cracking, delamination, fiber cracking, etc.). Neverthe-
tra of different patterns during their lifetime is not straightforward, less, the failure of adhesively-bonded composite joints is the result
although in order to increase design reliability the modeling of the of a dominant crack that, if monitored during fatigue life, can be an
behavior of structural elements must be accurately performed. acceptable damage metric [4]. In such cases fatigue crack growth
Numerous methods have been introduced to characterize the (FCG) curves are established to represent the fatigue behavior of
fatigue behavior of engineering materials and structures and devel- the examined joints.
op procedures to accurately model and predict their fatigue life. The FCG curves are plots of the stress intensity factor, SIF or K,
These methods can be classified into two main categories: those [5–7] or the strain energy release rate, SERR or G, [8–11] versus
based on the phenomenological representation of the material/ the crack propagation rate, da/dN, usually on logarithmic axes.
structural behavior (mainly expressed by the S–N curves and the Although the stress intensity factor is mainly used for the derivation
modeling/prediction based on this concept), and those based on a of FCG curves for metals/alloys, the strain energy release rate is pre-
damage metric representative of the structure’s durability. This ferred for composite materials, since for the calculation of G there is
damage metric is monitored (or measured, or calculated) during no need to directly calculate the local stress field close to the crack
fatigue loading and can indicate how close to failure the material tip, which is difficult if not impossible for composite laminates [12].
FCG curves show three regions: the first one, the subcritical region,
⇑ Corresponding author. Tel.: +41 216936393; fax: +41 216936240. during which the crack propagates very slowly under low G values
E-mail address: anastasios.vasilopoulos@epfl.ch (A.P. Vassilopoulos).
and occasionally can indicate a fatigue threshold; the second region
1359-835X/$ - see front matter Ó 2012 Elsevier Ltd. All rights reserved.
http://dx.doi.org/10.1016/j.compositesa.2012.05.004
1784 M. Shahverdi et al. / Composites: Part A 43 (2012) 1783–1790
during which a stable crack growth is observed and finally the third, for the fatigue life prediction of joints under realistic loading condi-
the unstable region, during which a small increase of G causes a tions. The proposed new approach is simple and accurate and
significant increase of the crack propagation rate. potentially it can be used for the modeling and subsequently the
Paris et al. [5] observed that in the second region, the relation- prediction of the total fatigue life of other composite materials.
ship between the crack propagation rate, da/dN, and the stress
intensity factor range, DK, or the maximum stress intensity factor,
Kmax, follows a power law equation. This observation was validated 2. Experimental investigation
by Mode I experimental data from three independent sources on
two aluminum alloys, 2024-T3 and 7075-T6. The Paris law has also 2.1. Material
been extensively applied for modeling fatigue crack propagation in
composite materials under pure Mode I [9,11,13–17], mixed Mode Adhesively-bonded pultruded GFRP DCB joints were examined
I/II [9,11,14,18–20], and pure Mode II [21], and for adhesively- under constant amplitude fatigue loads. The laminates, supplied
bonded structural joints [14,22–24]. by Fiberline A/S, Denmark, consisted of E-glass fibers embedded
Martin and Murri [8] introduced a phenomenological equation in isophthalic polyester resin, had a width of 40 mm and thickness
that is able to model the FCG behavior over the entire range of ap- of 6.0 mm, and comprised two outer combined mat layers and a
plied G, from the first to the third region. The derived model, des- roving layer in the symmetry plane. One combined mat consisted
ignated the ‘‘total fatigue life model’’, expresses the crack growth of two outer chopped strand mats, CSMs, and an inner woven 0°/
rate as a function of the maximum cyclic strain energy release rate, 90° fabric, all three stitched together. On the outside, a 40 g/m2
Gmax, the strain energy release rate threshold, Gth, and the critical polyester surface veil was added to protect against environmental
strain energy release rate, Gc. Shivakumar et al. [17] used the total attack. The fiber architecture of the laminates is shown in Fig. 1,
fatigue life model for characterizing the crack growth rate in glass/ which also gives an estimation of the nominal thickness of each
vinylester delaminated composite panels subjected to Mode I cyc- layer derived by optical microscopy. The fiber content, determined
lic loading. None of the abovementioned models takes into account by burn-off tests in accordance with ASTM D3171-99 [29], was
the effect of the R-ratio on the derived FCG curves however. 43.3 vol.% based on the fiber density of 2560 kg/m3 specified by
Experimental evidence proved that independent of the exam- the manufacturer and the assumption that no voids were present;
ined material or joint, FCG curves show similar trends. However, the fiber fractions are listed in Table 1. The weight of the second
contradictory results were found in the literature concerning the inner combined mat was almost double that of the first outer
effect of the R-ratio on the FCG curves. Nevertheless, most of the mat, and the proportion of woven fabrics was much higher. The
published experimental data are limited to the second region of longitudinal strength and Young’s modulus of the GFRP laminate
the FCG curve, e.g. [9,14,19,21,24,25], since it is very time-consum- were 307.5 ± 4.7 MPa and 25.0 ± 0.5 GPa respectively, as obtained
ing to estimate the fatigue threshold, and difficult to monitor the from tensile experiments according to ASTM D3039/D3039M-08
fast region close to Gc. The majority of publications on the subject, [30], see also [31].
e.g. [8,13,15,21,26], report that higher R-ratios result in steeper A two-component epoxy adhesive system was used, Sikadur
FCG curves, independent of the strain energy release rate parame- 330, supplied by Sika AG Switzerland, as the bonding material.
ter (Gmax, or DG) that is used for derivation of the curves. However, The tensile strength of the adhesive was 39.0 MPa and the stiffness
there are other experimental results showing FCG curves for differ- 4.6 GPa. The epoxy exhibited an almost elastic behavior and a brit-
ent R-ratios that are parallel to each other, e.g. [22,25]. tle failure under quasi-static tensile loading [32].
Regardless of the exhibited behavior, the crack propagation un-
der constant amplitude (CA) loading at any R-ratio was modeled 2.2. Experimental set-up and procedure
using the Paris law. Several models can be found in literature for
the simulation of the crack propagation only along the second The geometry of the DCB specimens used is shown in Fig. 2. The
region of the FCG curve, e.g. [6,16,22,27,28], incorporating the ef- specimen length was 250 mm including a pre-crack length of
fect of the R-ratio so that all data could be condensed into a single 50 mm measured from the loading line. A layer of approximately
master curve. Despite the fact that much research work has been 0.3 mm was mechanically abraded from all surfaces subjected to
devoted to the fatigue crack growth rate in composite materials, bonding to increase roughness and they were then chemically de-
no study exists in the literature regarding the modeling of the fati- greased using acetone. An additional 0.5 mm was abraded from
gue fracture behavior of pultruded glass fiber-reinforced polymer the upper arm only along the pre-crack to ensure that the crack
(GFRP) joints used in civil engineering structures. In addition, there would propagate between the two mat layers of the upper pultrud-
is no method able to model the effects of the R-ratio on the total ed laminate [31]. An aluminum frame was employed to assist the
fatigue life and predict the fatigue/fracture behavior of the exam-
ined joints under different loading conditions. The development
of such methods is hindered by the lack of complete databases con-
taining fatigue/fracture data regarding the total fatigue life, from
the subcritical to the unstable region.
A complete fatigue/fracture database containing 28 Mode I fati-
gue experiments of adhesively-bonded pultruded glass fiber-rein-
forced polymer DCB joints under different R-ratios has been
derived in this work. A new phenomenological fatigue crack growth
formulation is introduced in this study for the modeling of the
exhibited fatigue behavior. The model parameters were calibrated
by fitting the experimental FCG curves under R = 0.1, 0.5 and 0.8.
Then, the model was validated by predicting the FCG curves of
the joints under R = 0.3 and 0.65. It is shown here that if the model
parameters are estimated accurately, the model can be used for the
prediction of reliable FCG curves for several unknown loading con- Fig. 1. Fiber architecture of upper half of laminate cross section (transverse to
ditions and can therefore assist the development of methodologies pultrusion direction).
M. Shahverdi et al. / Composites: Part A 43 (2012) 1783–1790 1785
Table 1 The experimental process for all R-ratios comprised three steps:
Fiber architecture and fractions by volume and weight of pultruded laminates.
Layers Average thickness (mm) % By vol. % By weight Step 1: The specimen was inserted into the grips of the
Veil 2 0.05 a machine. The specimen was aligned and first the lower grip
First combined mat 2 0.63 and then the upper grip were tightened. The load introduced
CSM 2 1.7 2 2.5 due to this clamping process, less than 5 N, was manually set
Woven 0°/90° 2 1.6 2 2.3 to zero by adjusting the position of the moving rod of the test-
Second combined mat 2 1.07
CSM 2 2.6 2 3.8
ing rig.
Woven 0°/90° 2 4.1 2 6.0 Step 2: After specimen installation, a quasi-static loading ramp
Roving (UD) 1 2.5 1 23.3 1 34.2 was applied to initiate and propagate the crack up to around
Total 6.0 43.3 64.4 15–30 mm corresponding to the crack length required to reach
a
‘‘2x’’: On each side of the symmetry axis. the plateau in the R-curve of the examined specimen, see also
[31].
Step 3: The fatigue loading was started at a maximum displace-
ment, dmax, equal to the value of the maximum displacement
reached during the quasi-static loading. This facilitated the
recording of the initial fast crack propagation values corre-
sponding to the fast crack growth rate region of the FCG curve.
The loading was continued until crack growth rate values of
around 107 mm/cycle were attained. For the joints examined
here, this necessitated approximately 3 million fatigue cycles.
da/dN (mm/cycle)
increasing the number of points in the polynomial method effec-
tively decreased this sensitivity without changing the actual trend 10
-2
According to this theory, for a DCB joint with width B and an exist- -7
ing crack length, a, the SERR is a function of the maximum cyclic 10
200 400 600 800 1000
load, Pmax, and the rate of the compliance change, dC/da:
GImax(J/m2)
P2max dC
GImax ¼ ð1Þ Fig. 4. Crack growth rate versus GImax for Path II-B, solid lines are plots of model
2B da results.
Standard methods for the SERR calculation are based on this
equation, the difference between them basically being the way in
which the derivative dC/da is obtained. A thorough analysis of FCG curves converge to a value of around 600 J/m2 for Path II-A and
the applicability of several methods for the calculation of the SERR 1100 J/m2 for Path II-B. The GImax value obtained for Path II-B is the
to similar composite joints is presented in [33]. It was shown in same as the critical SERR (GIc) for Path II mentioned in [31]. No Path
[33] that for similar pultruded GFRP DCB joints, all methods give II-A failure mode was observed in [31]. Initially fiber bridging
similar results with the exception of simple beam theory. There- occurs for all specimens regardless of the R-ratio, and therefore
fore in the present work the experimental compliance method is for all experiments where the crack propagated along the same
used, according to which the measured dynamic compliance, path a similar SERR value was obtained. As the experiment devel-
(dmax/Pmax), is fitted to the determined crack length by the power oped however, the crack closure began breaking the fibers that
law equation C = kan. The maximum cyclic SERR can then be calcu- bridged the crack faces at lower R-ratios and consequently the
lated as: energy required for subsequent crack propagation was reduced.
Therefore, the differences between FCG curves under different R-
nPmax dmax ratios were more pronounced close to the fatigue threshold. Actu-
GImax ¼ ð2Þ
2Ba ally, absence of fiber bridging was the main reason for reaching
Correction factors for the loading blocks and moments resulting lower values for Gth under lower R-ratios, however, the loading
from large displacements were applied according to ASTM 5528-01 amplitude was the secondary reason.
(2007) [36].
3. Model development
2.3.5. Fatigue crack growth curves
The FCG curves for the examined R-ratios = 0.1, 0.5, and 0.8 are 3.1. Existing total life fatigue model
shown in Fig. 3 for Path II-A and Fig. 4 for Path II-B. A total of 24
experimental results (16 for Path II-A and 8 for Path II-B) are pre- A phenomenological equation for the calculation of the crack
sented in these figures. The results prove that the relationship be- growth rate as a function of the maximum cyclic strain energy re-
tween GImax and da/dN is highly dependent on the R-ratio. lease rate, the strain energy release rate threshold, and the static
Regardless of the crack path location, steeper curves reaching high- fracture toughness was first proposed by Martin and Murri [8]. This
er fatigue thresholds correspond to higher R-ratios. All the plotted model covers all three FCG regions: the subcritical around the fati-
gue threshold, the GImax-controlled region, and the critical region
close to GIc.
1
The model was based on the experimental FCG curves for each
10
R=0.1 R-ratio. Each FCG curve was divided into the three regions by visual
10
0 R=0.5 inspection. Then, parameters D and m were estimated by a linear
R=0.8
-1
regression analysis after fitting Eq. (3) to the middle region:
10
da/dN (mm/cycle)
da
10
-2 ¼ DðGI max Þm ð3Þ
dN
-3
10 In the subcritical region, the da/dN varies between zero and a
-4 value corresponding to the lowest value in region 2. The da/dN
10
equation can be written as follows:
-5
10 Q 1 !
da GIth
10
-6 ¼ DðGI max Þm 1 ð4Þ
dN GI max
-7
10
100 200 300 400 500 600 The exponent Q1 was determined using the already determined
2
GImax(J/m ) D and m by fitting the equation to the data in regions 1 and 2. A
trial and error approach was found to work well.
Fig. 3. Crack growth rate versus GImax for Path II-A, solid lines are plots of model In the unstable region, da/dN varies between infinite, when
results. GImax is equal to GIc, and the transition value corresponding to
M. Shahverdi et al. / Composites: Part A 43 (2012) 1783–1790 1787
D
imental data in regions 2 and 3. Finally, the combined da/dN equa- 10
-33
10
for three different R-ratios, i.e. R = 0.1, 0.5 and 0.8, for both Path
II-A and Path II-B:
25 8
1 GGIthImax
ðRÞ
da
ðRÞ ¼ DðRÞðGI max ÞmðRÞ 3 ð7Þ
dN 6
1 GGImaxIc
Table 2
Comparison of total fatigue life model parameters for Paths II-A and II-B from experimental investigation and proposed model.
1
10
500 Path II-A R=0.3
0 R=0.65
Path II-B 10
Prediction Eq.(7)
-1
Fitting to Ex. Eq. (6)
da/dN (mm/cycle)
400 10
-2
GIth (J/m2)
10
300 -3
10
-4
10
200
-5
10
-6
10
100
-7
10
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 100 200 300 400 500 600
R 2 GImax(J/m2)
Fig. 7. Effect of R-ratio on threshold strain energy release rate in Paths II-A and II-B. Fig. 8. Modeling validation by comparison of experimental results and modeling
prediction for Path II-A at R = 0.3 and R = 0.65.
10 R=0.9
2
mðRÞ ¼ 12:068R þ 7:354 ð15Þ 10
-2
-3
GIth ðRÞ ¼ 569:98R2 þ 120:67 ð16Þ 10
-4
10
for Path II-B.
The FCG curve for each desired R-ratio can be derived by Eq. (7) 10
-5
set of experimental data. As shown, the values derived by the new- 100 200 300 400 500 600
ly introduced model approximate well those derived after fitting GImax(J/m2)
each experimental data set with deviations of the order of 10%
maximum. The relative error which is used in Table 2, is calculated Fig. 9. Predicted FCG curves at various R-ratios for Path II-A based on proposed
as: model.
jExp Predj
Error ¼ 100% ð17Þ
Exp
on Eq. (7) after substituting the functions of the model parameters
for m and GIth, which depend linearly on R2. Since D was found given by Eqs. (11)–(13), are plotted in Fig. 8 by solid lines. The val-
to be an exponential function of R2, logarithms of the D values were ues of the model parameters estimated according to Eqs. (11)–(13)
used. are given in Table 3. Two experimentally derived FCG curves per
loading case, and the fitted lines (dashed lines, according to Eq.
3.3. Prediction of FCG curves for other R-ratios (6)) are also given for comparison. As shown, the predicted FCG
curves are validated by the experimental data and fitted lines.
Although the proposed model can be used for the prediction of The parameter values estimated according to the newly introduced
FCG curves under any R-ratio, in this study two intermediate R-ra- model are compared to the fitted ones, based on Eq. (6), in Table 3.
tios have been chosen. The predicted FCG curves for R-ratios equal The maximum error, see also Eq. (17), was less than 10% in all
to 0.3 and 0.65, corresponding to Path II-A crack propagation based cases.
M. Shahverdi et al. / Composites: Part A 43 (2012) 1783–1790 1789
10 R=0.6
R=0.7
10
-2 Acknowledgements
-3
10 This work has been supported by the Swiss National Science
10
-4 Foundation (Grant No. 200020-121756), Fiberline Composites
A/S, Denmark, supplier of the pultruded laminates, and Sika AG,
-5
10 Zurich, the adhesive supplier.
-6
10
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10
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