Experimental and theoretical modeling of shrinkage damage formation in fiber composites

The cure of a thermoset matrix in the formation of composites is always accompanied by chemical shrinkage that generates internal stresses. In composites with high fiber content, the matrix is cured under three-dimensionally constrained conditions. The results of the previous experimental and theoretical modeling of formation of shrinkage damage under these conditions in epoxy-amine systems are briefly discussed. The effect of the model geometry (tube and plate models), scale factor, cure schedule, and chemical structure of composites is analyzed. A theoretical model for predicting the possibility of formation of shrinkage damage in fiber composites is proposed. A regular square structure was considered. Analysis showed that the maximum level of shrinkage stress in the matrix at the ultimate fiber fraction ϕ+ was close to the stress level σ+ in an experimental long tube model, where the formation of shrinkage damage took place. The experimental results for the short tube model showed that the shrinkage damage in epoxy-amine systems occurred up to approximately σ+/3. The damage development took place within the whole range of fiber content from ϕ+ to ϕ* (where the shrinkage stress level was about σ+/3). In the long tube model, cohesive defects always nucleated inside the matrix. The damage grew, reached the inner surface of the tube, and then extended as adhesive debondings. A similar situation is expected in composites with a high fiber content. The damage considered is local, and the total monolithic character of a composite product is conserved.