Delamination is a common failure mode observed in ceramic matrix composites (CMCs) and occurs as a result of applied interlaminar tensile and shear stresses exceeding the interlaminar strength. As CMCs are further implemented into aero engines the need to understand their interlaminar failure becomes increasingly important. While significant contributions have been made toward understanding the mode I fracture toughness of CMCs, limited work exists on mode II. Several test methods for measuring the mode II fracture toughness have been proposed in literature, namely the end-notched flexure (ENF) and the end-loaded split (ELS) tests. This work investigates the mode II fracture toughness of a melt-infiltrated SiC/SiC CMC at ambient temperature using the ENF and ELS test methods. Acoustic emission (AE), direct current potential drop (DCPD), and digital image correlation (DIC) are implemented as health monitoring techniques to monitor crack initiation and propagation. Results show reasonable correlation between the two test methods and that the ELS test method is better suited for characterizing R-curve behavior.

The objective of this effort is to predict ceramic matrix composites (CMC) interlaminar Mode II Crack Growth Resistance (CGR), and the design of ASTM test specimen. Currently, there are a number of test standards and American Society for Testing and Materials (ASTM) for CMC’s at both ambient and elevated temperatures; however, there are no standardized test methods for determination of interlaminar shear (Mode II) fracture toughness in CMC’s. Although research work exists on interlaminar Mode II fracture toughness of CMC’s, the test methods applied showed definite drawbacks and limitations. Delamination Crack Growth (CGR) tests of CMC Mode II may exhibit zig-zag pattern, wavy cracks, fiber bridging, and premature specimen failure under bending load. The experimental parameters that may contribute to the difficulty can be summarized as specimen width and thickness, interface coating thickness, mixed mode failure evolution, and interlaminar defects. Modes II crack growth resistances, G II , were analytically and numerically determined at ambient temperature using end notched flexure (ENF) and the end-loaded split (ELS). Finite Element (FE) based. Multi-scale progressive failure analysis (MS-PFA) a combined Micro-mechanical damage and fracture mechanics Virtual Crack Closure Technique (VCCT) algorithms. Modeling of melt-infiltrated SiC/SiC CMC of ENF specimen (Laminate: with initial crack length was accomplished using a MS-PFA and VCCT approach. Test data were compared with MS-PFA prediction: a) Force vs. Crack Opening Displacement; and b) Mode II crack tip energy release rate vs. crack extension length for both edge and center line due to formation of Micro Crack Density Contribution, Crack Tip Stiffness Reduction; and c) zig-zag crack growth behavior (adhesive/cohesive). Next the ASTM Standard Proposed linear SGR equation was developed based on interpretation compliance technique from both MS-PFA Analysis and Test.

Ceramic matrix composite (CMC) materials are targeted for high temperature application in aircraft and power turbines, because of their low density and high-temperature thermo-mechanical properties, compared to conventional nickel super alloys. New test methods are needed for the assessment of the effects of delamination cracks on the structural integrity and life of CMC components. The ASTM C28 Fracture Toughness (Crack Growth Resistance – CGR) Working Group has drafted a standard test method for the “Mode I Interlaminar Fracture Tougness (G Ic – Crack Growth Resistance) of Fiber-Reinforced Ceramic Matrix Composites (CMC) by Wedge Loading of a Double Cantilever Beam at Ambient Temperatures” The wedge loading method was developed to avoid the problems of high temperature bonding of loading blocks and hinges. The ASTM test standard details the scope, use, and application of the test method, interferences, test equipment, specimen geometry and preparation, test procedures, data interpretation and calculation, and reporting requirements for the new CMC CGR test method.

A Durability and Damage Tolerance (D&DT) analysis of an S200 Nicalon/SiNC and Oxide/Oxide Ceramic Matrix Composite (CMC) was conducted to determine the crack growth resistance (GIc) of Wedge Loaded DCB (WDCB) at Room and Elevated temperatures (RT/ET) and compared with experimental tests observations. Wedge Loading gives proper crack path without mixed mode effects and can be used at high temperature in a furnace. Load displacement, GIc, electrical resistivity and acoustic emission was measured by tests and compared to FE based Multi Scale Progressive Failure Analysis (PFA) of the WDCB specimen. The critical damage events studied included damage initiation, damage propagation, fracture initiation, and fracture propagation as the components were being loaded. Effect of defects on Modulus (E11, E22, and E33) was conducted by Electrical Resistance (ER) Measurement at Room temperature (RT). Multi-Scale modeling simulation considered de-homogenized nano-assisted micromechanics analytical formulation, a Mori Tanaka based stiffness correction including void shape, size, distribution and orientation effects. Emitted/received signal amplitude by ER Vs. time was used to evaluate reduction of stiffness in all directions resulting in anisotropic stiffness of As-Built specimens. WDCB specimen was tested to failure at RT/ET to produce reliable GIc values with minimum specimen size. Many parameters that contribute to specimen failure included interface coating thickness, mixed mode failure evolution, interlaminar defects, delamination damage, crack bridging, and fiber fracture which were all studied in detail in this work. All simulations correlated well with test.

A Durability and Damage Tolerance (D&DT) analysis of an S200 Nicalon/SiNC CVI SiC/SiC attachment joint was conducted to determine the CMC components material structural integrity during service loading. A building block validation strategy is proposed that includes: (i) Room, and High Temperature (RT/HT) testing with AE (Acoustic Emission) and ER (Electrical Resistivity) strategies; (ii) Advanced multi-scale modeling; (iii) Interpretation test/model; and (iv) ASTM draft submittal of simplified beam equation supported by FEM/test compliance and round robin exercise. The following building block calibration, verification, validation, and accreditation strategy were performed: 1 ) Material characterization analysis to determine the damage evolution under uniaxial tensile loads and compared with test; 2 ) Crack Growth Resistance (CGR) analysis and test of wedge loaded DCB (Double Cantilever Beam) to determine the crack growth length, zig-zag pattern, fracture, shift in failure mechanisms and derivation of fracture energy vs. crack length simple formulation at RT; 3 ) Joint loading multi scale modeling and comparison with observed test load displacement curve, and determination of fracture energy; and 4 ) blade structural integrity and response under service loading using Multi-Scale Progressive Failure Analysis (MS-PFA) and determination of contributing damage and delamination types and their locations. FE based MS-PFA of the material and structure studied addressed the critical damage events (damage initiation, damage propagation, fracture initiation, and fracture propagation) as the components were being loaded. All dehomogenized multi scale methods CMC parameters were implemented in the material and structural modeling strategy, such as crack density effects and architecture (2D, 3D orthogonal, and mixed) interphase thickness, and interfacial shear strength. Many parameters that contribute to specimen failure including interface coating thickness, mixed mode failure evolution, interlaminar defects, delamination damage, crack bridging, and fiber fracture were all studied in detail in this work. Several FE-based multi-scale modeling techniques were investigated: a) MS-PFA; b) Virtual Crack Closure Technique (VCCT); and c) integrated damage and fracture evolution methodology using combined MS-PFA and VCCT.

Interlaminar fracture properties play an important role in predicting failure of structural components for CMC materials. In engine applications, components are subject to large thermal gradients which induce interlaminar stresses. One of the main challenges in evaluating interlaminar fracture toughness at room and elevated temperatures is the development of an experimental setup that provides ease for testing and allows for in-situ monitoring of the interlaminar crack growth. Therefore, a wedge-loaded DCB testing method is developed. The method utilize electrical resistance to monitor crack growth and was applied to a woven polymer infiltrated pyrolysis (PIP) SiC/SiNC composite. Post-testing inspection was carried out using optical microscopy of polished cross-sections, showing crack morphology. It was found that crack growth rate at room temperature is double the one at 815 °C for initial tests in this composite system. Estimates of Mode I energy release rate suggests flat R-curve behavior at room temperature in comparison to rising R-curve behavior at 815 °C.

ASTM test standards for CMC’s Crack Growth Resistance (CGR) may exhibit a zig-zag (wavy) crack path pattern, and fiber bridging. The experimental parameters that may contribute to the difficulty can be summarized as: specimen width and thickness, interface coating thickness, mixed mode failure evolution, and interlaminar defects. Modes I crack growth resistances, G I were analytically determined at ambient temperature using wedge test, a modified double cantilever beam (DCB). Several Finite Element (FE) based Multi-scale modeling potential techniques were investigated: a ) Multi-scale progressive failure analysis (MS-PFA); b ) Virtual Crack Closure Technique (VCCT). Advantages and disadvantages of each were identified. The final modeling algorithm recommended was an integrated damage and fracture evolution methodology using combined MS-PFA and VCCT. The material tested in this study was a slurry-cast melt-infiltrated SiC/SiC composite with Tyranno ZMI fibers (Ube Industries, Kyoto, Japan) and a BN interphase. The fiber architecture consisted of eight plies of balanced 2-D woven five-harness satin. The total fiber volume fraction was about 30% with half of the fibers in the 0° direction and half in the 90° direction. All specimens had a nominal thickness of 4 mm. An alumina wedge with 18° head angle (2 α ) was used. In this method, a splitting force is created by inserting a vertically-moving wedge in a notch causing the arms to separate and forcing an interlaminar crack at the sharpest end of the notch The MS-PFA numerical model predicted the damage and fracture evolution and utilized the GENOA UMAT (User Material Subroutine) for Damage and FEM (Finite Element Model) stress intensity and LEFM (Linear elastic Fracture Model), Cohesive Model for Fracture. The analysis results (Fracture energy vs. crack length, Fracture energy vs. load, Fracture energy vs. crack opening displacement) matched the Mode I coupon tests and revealed the following key findings. Mode I-Wedge specimen exhibits: 1 ) failure mode is due to interlaminar tension (ILT) only in the interface section and a zig-zag pattern observed; 2 ) VCCT crack growth resistance is well matched to the test data; and 3 ) failure mode is a mixed mode behavior of Interlaminar tension (ILT) to interlaminar shear (ILS). The final Wedge test specimen configuration optimization includes the sensitivity of design parameters to CGR: a ) wedge contact coefficient of friction; b ) lever arms thickness, and c ) inclined head angle, distance between the initial crack and wedge tip.

The objective of this effort is to develop and demonstrate innovative interlaminar Mode I and Mode II fracture toughness analysis and test methods for ceramic matrix composites (CMC). Currently, there are number of American Society for Testing and Materials (ASTM) test standards for CMC’s at both ambient and elevated temperatures, including interlaminar tension and shear strength test methods. However, there are no standardized test methods for determination of interlaminar fracture toughness in CMC’s. Although research work exists on interlaminar Mode I and Mode II fracture toughness of various types of CMC’s, the test methods applied particularly in Mode II fracture toughness testing showed definite drawbacks and limitations. ASTM test standards for CMC’s may exhibit a zig-zag (wavy) crack path pattern, and fiber bridging. The experimental parameters that may contribute to the difficulty can be summarized as: specimen width and thickness, interface coating thickness, mixed mode failure evolution, and interlaminar defects. Modes I and II crack growth resistances, G I and G II , were analytically determined at ambient temperature using double cantilever beam (DCB) and End Notched Flexure (ENF) geometries. Three (3) CMC material systems were analyzed (Sylramic/IBN/MI, SiC/SiC CVI, and SiC/CAS). Several Finite Element (FE) based potential techniques were investigated: a) Multi-scale progressive failure analysis (MS-PFA); b) Virtual Crack Closure Technique (VCCT); and c) Contour Integral (CI). Advantages and disadvantages of each were identified. The final modeling algorithm recommended was an integrated damage and fracture evolution methodology using MS-PFA and VCCT. The analysis results ( Fracture energy vs. crack length, Fracture energy vs. load, Fracture energy vs. crack opening displacement) matched the Mode I and Mode II coupon tests and revealed the following key findings. Mode I-DCB specimen: 1) Sylramic/IBN/MI failure mode is due to interlaminar tension (ILT) only in the interface section and a zig-zag pattern observed 2) VCCT crack growth resistance of Sylramic/IBN/MI is well matched to the test data and 3) SiC/SiC CVI failure mode is a mixed mode behavior (ILT to interlaminar shear (ILS). Mode II ENF specimen MS-PFA analysis suggests mixed mode behavior and the zig-zag pattern similar to Mode I coupon tests.

A simple analytical model is derived for the prediction of time dependent deformation and damage response of metal matrix composites under fiber direction loading. The model can be used in conjunction with a number of viscoplastic constitutive models to describe the matrix material behavior. Damage in the form of progressive fiber fractures is incorporated using a mechanistic approach. The criterion for fiber fractures can be based on statistical information on fiber strength. When used in conjunction with a prescribed failure condition for a composite, the model provides a means for predicting composite life under general thermomechanical load conditions. Based on comparison of results with detailed finite element analyses and with laboratory test data, it appears that the simple model provides reasonably accurate predictions.

A mechanistic modeling approach for material characterization and for life prediction of CMC components is described. The approach includes consideration of environment-induced degradation of CMC properties, progressive microcracking of the matrix material and interfacial damage. The mechanistic model has been embedded in a finite element analysis (FEA) framework to enable structural analyses of components and to analyze macro damage, such as cracks and delaminations. This paper describes the modeling approach and its application in the study of substructures. Examples include analyses of simple test specimen coupons, stress concentration at holes and a structural element configuration of a 2D woven SiC/SiC composite. The results include predicted and measured strain field near circular holes and global load-displacement behavior of structural elements. In each case, the model predictions are compared with the experimental measurements.