As a first step towards a new crack healing methodology for cyclic loading, this paper examines two promising crack-tip shielding mechanisms during fatigue of a microcapsule toughened epoxy. Artificial crack closure is achieved by injecting precatalyzed monomer into the crack plane to form a polymer wedge at the crack tip. The effect of wedge geometry is also considered, as dictated by crack loading conditions during infiltration. Crack-tip shielding by a polymer wedge formed with the crack held open under the maximum cyclic loading condition (K max ) yields temporary crack arrest and extends the fatigue life by more than 20 times. Hydrodynamic pressure and viscous damping as a mechanism of crack tip shielding are also investigated by injecting mineral oil into the crack plane. Viscous fluid flow leads to retardation of crack growth independent of initial loading conditions. The success of these mechanisms for retarding fatigue crack growth demonstrates the potential for in situ self-healing of fatigue damage.Keywords: A. smart materials, A. polymer-matrix composites, B. fatigue, C. failure criterion, self-healing Submitted for publication in Composites Science and Technology (2005) 2
IntroductionThermosetting polymers are used in a wide variety of applications ranging from structural composites to microelectronics. Due to low strain-to-failure, these polymers are highly susceptible to damage in the form of cracks. In structural composites these cracks can lead to fiber/matrix debonding and inter-ply delamination, ultimately resulting in component failure. Susceptibility to cyclic loading is particularly problematic because a crack will grow, however slowly, above a threshold range of stress intensities ΔK th that is significantly lower than the critical stress intensity K IC . Prevention of fatigue failure currently depends on accurate life prediction and implementation of inspection procedures.Polymer fatigue has been studied extensively in both homogeneous and composite structures (e.g., [1][2][3][4][5][6][7][8][9][10][11][12][13][14][15]). In most polymers, fatigue crack growth rates (da/dN) are accurately described by the Paris power law [16],where C 0 and n are material constants and ΔK I is the applied range of stress intensity. Typical Paris power law crack growth behavior is shown schematically by the solid curve in Fig. 1. Despite this understanding of cyclic crack growth, fatigue failure remains a major cause of component failure. Fig. 1. Representative relationship between fatigue crack growth rate (da/dN) and the applied stress intensity range (ΔK I ) in the Paris power law region. Improved fatigue behavior can be obtained by: (a) increasing the range of stress intensity before crack growth instability ΔK ult , (b) reducing the crack growth rate da/dN for a given ΔK I , (c) reducing the crack growth rate sensitivity to ΔK I , i.e. reduce n, or (d) increasing the threshold ΔK th at which crack growth arrests.Strategies for improving fatigue life are shown schematically in Fig. 1 and includ...