Pre-strained composite test coupons

• US 10,190,954 B2
• Filed: 06/01/2015
• Issued: 01/29/2019
• Est. Priority Date: 06/01/2015
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Esposito, Jack J., Tucker, Samuel J.
• Primary Examiner(s): Dunlap, Jonathan
• Application Number:
  US14/727,236
• Publication Number:
  US 20160349160A1
• Time in Patent Office: 1,338 Days
• Field of Search: 73826, 73827, 73833, 73834, 73788, 73799, 73789, 73802
• CPC Class Codes: B29C 66/721 Fibre-reinforced materials B29C66/729 takes precedence
• CPC Class Codes: B29C 66/7212 characterised by the composition of the fibres
• CPC Class Codes: B29C 70/202 arranged in parallel planes or structures of fibres crossing at substantial angles, e.g. cross-moulding compound [XMC] B29C70/207 takes precedence
• CPC Class Codes: B29C 70/207 arranged in parallel planes of fibres crossing at substantial angles
• CPC Class Codes: B29C 70/228 the structure being stacked in parallel layers with fibres of adjacent layers crossing at substantial angles
• CPC Class Codes: G01N 2203/0017 Tensile
• CPC Class Codes: G01N 2203/006 Crack, flaws, fracture or rupture
• CPC Class Codes: G01N 2203/0062 Crack or flaws
• CPC Class Codes: G01N 2203/0073 Fatigue
• CPC Class Codes: G01N 2203/0075 Strain-stress relations or elastic constants
• CPC Class Codes: G01N 2203/0091 Peeling or tearing
• CPC Class Codes: G01N 2203/0096 Fibre-matrix interaction in composites
• CPC Class Codes: G01N 2203/0208 Specific programs of loading, e.g. incremental loading or pre-loading
• CPC Class Codes: G01N 2203/0252 Monoaxial, i.e. the forces being applied along a single axis of the specimen
• CPC Class Codes: G01N 2203/028 One dimensional, e.g. filaments, wires, ropes or cables
• CPC Class Codes: G01N 2203/0282 Two dimensional, e.g. tapes, webs, sheets, strips, disks or membranes
• CPC Class Codes: G01N 2203/0298 Manufacturing or preparing specimens
• CPC Class Codes: G01N 2291/0231 Composite or layered materials
• CPC Class Codes: G01N 2291/0258 Structural degradation, e.g. fatigue of composites, ageing of oils
• CPC Class Codes: G01N 3/08 by applying steady tensile or compressive forces G01N3/28 takes precedence
• CPC Class Codes: G01N 3/18 : Performing tests at high or low temperatures

Abstract

A composite test coupon includes a plurality of plies. The plurality of plies include first ply layers and second ply layers. The first ply layers have first fibers and a substantially uniform matrix material associated with the first fibers. The second ply layers have second fibers and a pre-stressed matrix material associated with the second fibers. The first fibers are oriented in a first direction, and the second fibers are oriented in a second direction that is different from the first direction. The pre-stressed matrix material includes stress induced cracks between the second fibers of each of the second ply layers.

Claims

1. A method comprising:

inserting a test coupon of a composite material having a plurality of layers into a testing device that has a first element to secure the test coupon and a second element to secure the test coupon, wherein the plurality of layers of the test coupon are arranged in a cross-ply layup including;

inner ply layers having first fibers and a first matrix material associated with the first fibers, the first fibers oriented in a first direction; and

outer ply layers having second fibers and a second matrix material associated with the second fibers, the outer ply layers including outermost ply layers and the second fibers oriented in a second direction that is different than the first direction;

performing a first loading operation on the test coupon, wherein the first loading operation includes applying a first tensile load oriented in the first direction, the first tensile load corresponding to a threshold load that is less than a failure load of the first fibers;

removing the first tensile load after the first tensile load causes cracking along the second direction and between the second fibers of each of the outermost ply layers;

after removing the first tensile load, performing a second loading operation on the test coupon, wherein the second loading operation includes increasing tensile loading of the test coupon to the failure load of the first fibers;

receiving, from the testing device, strain values of the test coupon during tensile loading of the test coupon; and

determining one or more modulus values associated with a first contribution corresponding to the inner ply layers based on the strain values and based on a nominal thickness of a ply area associated with the inner ply layers, the first contribution independent of a second contribution of the outer ply layers.

2. The method of claim 1, further comprising determining one or more tensile strength values associated with the first contribution corresponding to the inner ply layers based on the nominal thickness of the ply area associated with the inner ply layers.

3. The method of claim 2, wherein the threshold load is greater than ninety percent of the failure load and less than or equal to ninety-nine percent of the failure load.

4. The method of claim 1, wherein the test coupon does not include adhesive tabs for securing the test coupon to the first element and to the second element of the testing device.

5. The method of claim 1, wherein the first loading operation and the second loading operation are performed above a temperature threshold, above a humidity threshold, or a combination thereof.

6. The method of claim 1, further comprising, prior to performing the first loading operation, using the testing device to determine the failure load using a sacrificial test coupon that is substantially similar to the test coupon.

7. The method of claim 1, wherein the threshold load is in a range of about 85 percent to about 99 percent of the failure load.

8. The method of claim 1, wherein the first element of the testing device includes a first friction pad to secure directly to a first end of the test coupon, and wherein the second element of the testing device includes a second friction pad to secure directly to a second end of the test coupon.

9. The method of claim 1, wherein the removing the first tensile load includes completely removing the first tensile load such that the test coupon experiences no tensile load.

10. The method of claim 1, wherein the determining the one or more modulus values is based on a second order polynomial equation, the second order polynomial equation indicating a nonlinear relationship between the one or more modulus values and each strain value of the strain values.

11. The method of claim 1, wherein the first tensile load is less than a second tensile load, the second tensile load less than the failure load of the first fibers, and wherein the first loading operation further comprises:

applying the second tensile load oriented in the first direction, the second tensile load less than a third tensile load, the third tensile load less than the failure load of the first fibers; and

applying the third tensile load oriented in the first direction, the third tensile load corresponding to the threshold load.

12. The method of claim 11, wherein the first tensile load is less than or equal to twenty-five percent of the failure load, wherein the second tensile load is greater than twenty-five percent of the failure load and less than or equal to fifty percent of the failure load, and wherein the threshold load is equal to ninety percent of the failure load.

13. The method of claim 1, wherein the threshold load is indicative of a substantial amount of cracks formed in the second matrix material, and further comprising, prior to performing the second loading operation, determining the substantial amount of cracks by performing an acoustic testing operation on the test coupon, wherein the second contribution is based on the substantial amount of cracks, and wherein, in a determination of the one or more modulus values, the second contribution is ignored or the second contribution is removed.

14. A system comprising:

a processor; and

a memory in communication with the processor, the memory including instructions executable by the processor to perform operations including;

communicating with a testing device that is configured to perform load testing operations on a test coupon of a composite material having a plurality of layers, wherein the plurality of layers of the test coupon are arranged in a cross-ply layup including;

inner ply layers having first fibers and a first matrix material associated with the first fibers, the first fibers oriented in a first direction; and

outer ply layers having second fibers and a second matrix material associated with the second fibers, the outer ply layers including outermost ply layers and the second fibers oriented in a second direction that is different than the first direction;

sending a first set of instructions to the testing device to perform a first loading operation on the test coupon, wherein the first loading operation includes applying a first tensile load oriented in the first direction, the first tensile load corresponding to a threshold load that is less than a failure load of the first fibers;

removing the first tensile load after the first tensile load causes cracking along the second direction and between the second fibers of each of the outermost ply layers, the removing including causing a magnitude of the first tensile load to be zero;

after removing the first tensile load, sending a second set of instructions to the testing device to perform a second loading operation on the test coupon, wherein the second loading operation includes increasing tensile loading of the test coupon to the failure load of the first fibers;

receiving, from the testing device, strain values of the test coupon during tensile loading of the test coupon to the failure load; and

calculating one or more modulus values associated with a first contribution corresponding to the inner ply layers based on the strain values and based on a nominal thickness of a ply area associated with the inner ply layers, the first contribution independent of a second contribution associated with the outer ply layers.

15. The system of claim 14, wherein the threshold load is greater than ninety percent of the failure load and less than or equal to ninety-nine percent of the failure load.

16. The system of claim 14, wherein the testing device includes a first element to secure the test coupon and a second element to secure the test coupon, wherein the first element of the testing device includes a first friction pad to secure directly and intimately to a first end of the test coupon, and wherein the second element of the testing device includes a second friction pad to secure directly and intimately to a second end of the test coupon, wherein the first element and the second element secure directly and intimately to the outermost ply layers having second fibers oriented in a nominal 90 degree direction.

17. The system of claim 14, wherein the first loading operation is separate and distinct from the second loading operation.

18. A system comprising:

a processor; and

a memory in communication with the processor, the memory including instructions executable by the processor to perform operations including;

communicating with a testing device that is configured to perform load testing operations on a test coupon of a composite material having a plurality of layers, wherein the plurality of layers of the test coupon are arranged in a cross-ply layup including;

inner ply layers having first fibers and a first matrix material associated with the first fibers, the first fibers oriented in a first direction; and

outer ply layers having second fibers and a second matrix material associated with the second fibers, the outer ply layers including outermost ply layers and the second fibers oriented in a second direction that is different than the first direction;

sending a first set of instructions to the testing device to perform a first loading operation on the test coupon, wherein the first loading operation includes applying a first tensile load oriented in the first direction, the first tensile load corresponding to a threshold load that is less than a failure load of the first fibers;

removing the first tensile load after the first tensile load causes cracking along the second direction and between the second fibers of each of the outermost ply layers, the removing including causing a magnitude of the first tensile load to be zero;

after removing the first tensile load, sending a second set of instructions to the testing device to perform a second loading operation on the test coupon, wherein the second loading operation includes increasing tensile loading of the test coupon to the failure load of the first fibers; and

calculating one or more tensile strength values associated with a first contribution corresponding to the inner ply layers based on a nominal thickness of a ply area associated with the inner ply layers, the first contribution independent of a second contribution associated with the outer ply layers.