Fiber-reinforced products, renowned for their superior mechanical properties, find extensive applications in aerospace, transportation, and other fields. Single-filament wound (SFW) products suffer from uneven stress distribution due to fiber cross undulations within the same layer, limiting fiber strength utilization. In contrast, multi-filament wound (MFW) products exhibit a parallel arrangement of fibers, which helps avoid stress concentration and enhances impact resistance. Given that interlayer fracture is a critical failure mode affecting product performance, the interlayer performance and fracture mechanisms of MFW products were investigated in this study. A novel specimen preparation method was introduced, taking into account factors such as the winding process, tension control, and resin content. The fracture morphology of the specimen was analyzed to elucidate the relationship between fracture behavior and the winding structure, layer density, and specimen thickness. Results show that the fracture toughness of 5-mm-thick SFW specimens is 28.49% higher than that of MFW specimens. The interlayer pore defects have a greater impact on samples with lower single-layer fiber thickness, where a 20% reduction in single-layer fiber thickness results in a 22.3% decrease in the average strain energy release rate. Decreasing the specimen thickness increases flexibility, facilitating crack propagation along defect areas.
ChawlaVPuplampuSBHopperW, et al.Splitting mode-I fracture toughness of carbon fibers using nanoindentation. Carbon2024; 219: 118777. DOI: 10.1016/j.carbon.2023.118777.
2.
YesuASrivastavaMAgnihotriPK, et al.Minimizing environmental degradation in fracture toughness of carbon fiber/epoxy composites using carbon nanotubes. Eng Fract Mech2023; 294: 109734. DOI: 10.1016/j.engfracmech.2023.109734.
3.
SimaafrookhtehSTsokanasPLoutasT, et al.Measuring the interlaminar fracture toughness of thin carbon fiber/polyamide6 composites using adhesively bonded stiffeners. Compos Appl Sci Manuf2024; 176: 107841. DOI: 10.1016/j.compositesa.2023.107841.
4.
YildirimCUlusHBeylergilB, et al.Effect of atmospheric plasma treatment on mode-I and mode-II fracture toughness properties of adhesively bonded carbon fiber/PEKK composite joints. Eng Fract Mech2023; 289: 109463. DOI: 10.1016/j.engfracmech.2023.109463.
5.
ChenQWuFJiangZ, et al.Improved interlaminar fracture toughness of carbon fiber/epoxy composites by a combination of extrinsic and intrinsic multiscale toughening mechanisms. Compos B Eng2023; 252: 110503. DOI: 10.1016/j.compositesb.2023.110503.
6.
AbdallaFHMutasherSAKhalidYA, et al.Design and fabrication of low cost filament winding machine. Mater Des2007; 28: 234–239. DOI: 10.1016/j.matdes.2005.06.015.
7.
Vargas-RojasE. Prescriptive comprehensive approach for the engineering of products made with composites centered on the manufacturing process and structured design methods: review study performed on filament winding. Compos B Eng2022; 243: 110093. DOI: 10.1016/j.compositesb.2022.110093.
8.
AzeemMYaHHAlamMA, et al.Application of filament winding technology in composite pressure vessels and challenges: a review. J Energy Storage2022; 49: 103468. DOI: 10.1016/j.est.2021.103468.
9.
FuJYunJKimJ-S, et al.Real-time graphic visualization of filament band winding for fiber-reinforced cylindrical vessels. J Compos Mater2016; 50: 2165–2175. DOI: 10.1177/0021998315602325.
10.
QiSAlajarmehOShelleyT, et al.Formation of non-uniform fibre distributions in winding-pultrusion process and its effect on axial compressive properties of hollow GFRP profiles. Compos Appl Sci Manuf2023; 173: 107659. DOI: 10.1016/j.compositesa.2023.107659.
11.
DaiYZhengCLinJ, et al.Winding pattern design of composite cylinders considering the effect of fiber stacking. Compos B Eng2024; 275: 111306. DOI: 10.1016/j.compositesb.2024.111306.
12.
MorozovEV. The effect of filament-winding mosaic patterns on the strength of thin-walled composite shells. Compos Struct2006; 76(1): 123–129.
13.
VasilievVVMorozovEV. Mechanics and analysis of composite materials. Amsterdam, Netherlands: Elseiver, 2001.
14.
ZhaoXLiangJZhaoC, et al.Experimental and numerical analysis of low-velocity impact behavior of wound products using multi-filament winding technique. J Mater Res Technol2023; 25: 7292–7306. DOI: 10.1016/j.jmrt.2023.07.159.
15.
WuQZuLWangP, et al.Design and fabrication of carbon-fiber-wound composite pressure vessel with HDPE liner. Int J Pres Ves Pip2022; 200: 104851. DOI: 10.1016/j.ijpvp.2022.104851.
16.
ZuLKoussiosSBeukersA. Design of filament-wound circular toroidal hydrogen storage vessels based on non-geodesic fiber trajectories. Int J Hydrogen Energ2010; 35: 660–670. DOI: 10.1016/j.ijhydene.2009.10.062.
17.
HuZChenMZuL, et al.Investigation on failure behaviors of 70 MPa Type IV carbon fiber overwound hydrogen storage vessels. Compos Struct2021; 259: 113387. DOI: 10.1016/j.compstruct.2020.113387.
18.
BłachutAKaletaJDetynaJ, et al.Multiscale analysis of composite pressure vessel structures wound with different fiber tensile force. Compos Struct2024; 337: 118065. DOI: 10.1016/j.compstruct.2024.118065.
19.
ZhaoXLiangJLiuJ, et al.A novel multi-filament winding technique for type III composite pressure vessel: from CFRP cross-undulation concept to structural performance validation. Int J Hydrogen Energy2023; 48: 17237–17250. DOI: 10.1016/j.ijhydene.2023.01.258.
20.
LiXYuanY. Hybrid and gradient design of ultra-thin-ply composite laminates for synergistic suppression of delamination and fiber fracture damage modes. Eng Fract Mech2024; 295: 109822. DOI: 10.1016/j.engfracmech.2023.109822.
21.
Syed AbdullahSIBBoktiSKWongKJ, et al.Mode II and mode III delamination of carbon fiber/epoxy composite laminates subjected to a four-point bending mechanism. Compos B Eng2024; 270: 111110. DOI: 10.1016/j.compositesb.2023.111110.
22.
YaoLChuaiMLyuZ, et al.A proposal for similitude in characterizing fatigue delamination behavior with fibre bridging of carbon-fibre reinforced polymer composites. Eng Fract Mech2024; 295: 109756. DOI: 10.1016/j.engfracmech.2023.109756.
23.
OuYangQWangXLiuL. High crack self-healing efficiency and enhanced free-edge delamination resistance of carbon fibrous composites with hierarchical interleaves. Compos Sci Technol2022; 217: 109115. DOI: 10.1016/j.compscitech.2021.109115.
24.
GongYJiangLLiL, et al.An experimental and numerical study of the influence of temperature on mode II fracture of a t800/epoxy unidirectional laminate. Materials2022; 15: 8108. DOI: 10.3390/ma15228108.
25.
OuYWuLMaoD. Hierarchical mode I interlaminar toughening of unidirectional CFRP laminates by the synergistic effects of CNT powders and veils. Compos Appl Sci Manuf2023; 168: 107464. DOI: 10.1016/j.compositesa.2023.107464.
26.
ZhangXShiYLiZ-X. Experimental study on the tensile behavior of unidirectional and plain weave CFRP laminates under different strain rates. Compos B Eng2019; 164: 524–536. DOI: 10.1016/j.compositesb.2019.01.067.
27.
HosoiASakumaSFujitaY, et al.Prediction of initiation of transverse cracks in cross-ply CFRP laminates under fatigue loading by fatigue properties of unidirectional CFRP in 90° direction. Compos Appl Sci Manuf2015; 68: 398–405. DOI: 10.1016/j.compositesa.2014.10.022.
28.
OuYFuAWuL, et al.Enhanced interlaminar fracture toughness of unidirectional CFRP laminates with tailored microstructural heterogeneity of toughening layer. Compos Appl Sci Manuf2024; 176: 107872. DOI: 10.1016/j.compositesa.2023.107872.
29.
OuYGonzálezCVilatelaJJ. Understanding interlaminar toughening of unidirectional CFRP laminates with carbon nanotube veils. Compos B Eng2020; 201: 108372. DOI: 10.1016/j.compositesb.2020.108372.
30.
SongWChenYMuZ, et al.A feather-inspired interleaf for enhanced interlaminar fracture toughness of carbon fiber reinforced polymer composites. Compos B Eng2022; 236: 109827. DOI: 10.1016/j.compositesb.2022.109827.
31.
Rodríguez-GarcíaVHerráezMMartínezV, et al.Interlaminar and translaminar fracture toughness of automated manufactured bio-inspired CFRP laminates. Compos Sci Technol2022; 219: 109236. DOI: 10.1016/j.compscitech.2021.109236.
32.
ZhangFLiuXYeY, et al.Effect of gap and overlap on mode II interlaminar fracture toughness of automated fiber placement prepreg laminates. Chin J Aeronaut2023; 36: 390–401. DOI: 10.1016/j.cja.2023.04.025.
33.
ZhouYCaoYCaoJ, et al.Fracture toughness and fiber bridging mechanism for mode-I interlaminar failure of spread-tow woven composites. Eng Fract Mech2024; 298: 109957. DOI: 10.1016/j.engfracmech.2024.109957.
34.
UmarfarooqMAShivakumar GoudaPSVeeresh KumarGB, et al.Impact of process induced residual stresses on interlaminar fracture toughness in carbon epoxy composites. Compos Appl Sci Manuf2019; 127: 105652. DOI: 10.1016/j.compositesa.2019.105652.
35.
PerniceMFDe CarvalhoNVRatcliffeJG, et al.Experimental study on delamination migration in composite laminates. Compos Appl Sci Manuf2015; 73: 20–34. DOI: 10.1016/j.compositesa.2015.02.018.
36.
XuJ. Crashworthiness of carbon fiber hybrid composite tubes molded by filament winding. Compos Struct2016; 139: 130–140.
37.
MindermannP. Pultrusion-winding: a novel fabrication method for coreless wound fiber-reinforced thermoset composites with distinct cross-section. Composites Part A2022; 154(5): 106763.
38.
JiY. Real-time in-situ process monitoring method based on the self-conductivity of carbon fiber prepreg for automated fiber placement (AFP). Composites Part B2024; 276: 111356.
39.
LiangJXueYLiY, et al. Design of continuous transition line pattern between layers of composite pressure vessel. J Reinforc Plast Compos. 2024; 1-4: 07316844241226548. doi:10.1177/07316844241226548.
40.
AlifNCarlssonLABooghL. The effect of weave pattern and crack propagation direction on mode I delamination resistance of woven glass and carbon composites. Compos B Eng1998; 29: 603–611. DOI: 10.1016/S1359-8368(98)00014-6.
41.
BłachutAWollmannTPanekM, et al.Influence of fiber tension during filament winding on the mechanical properties of composite pressure vessels. Compos Struct2023; 304: 116337. DOI: 10.1016/j.compstruct.2022.116337.
42.
StablaPLubeckiMSmolnickiM. The effect of mosaic pattern and winding angle on radially compressed filament-wound CFRP composite tubes. Compos Struct2022; 292: 115644. DOI: 10.1016/j.compstruct.2022.115644.
43.
GuoKChenSWenL, et al.Prediction of dome thickness for composite pressure vessels from filament winding considering the effect of winding pattern. Compos Struct2023; 306: 116580. DOI: 10.1016/j.compstruct.2022.116580.
44.
PoultonMSebastianWMMottramJT. DIC study of strain concentrations and damage within web-flange junctions of pultruded GFRP bridge decking. Compos Appl Sci Manuf2024; 179: 108011. DOI: 10.1016/j.compositesa.2024.108011.
RamakrishnanKRCornSLe MoigneN, et al.Experimental assessment of low velocity impact damage in flax fabrics reinforced biocomposites by coupled high-speed imaging and DIC analysis. Compos Appl Sci Manuf2021; 140: 106137. DOI: 10.1016/j.compositesa.2020.106137.
47.
YanXGuoXGaoY, et al.Mode-II fracture toughness and crack propagation of pultruded carbon fiber-epoxy composites. Eng Fract Mech2023; 279: 109042. DOI: 10.1016/j.engfracmech.2022.109042.
48.
De MouraMFSFSilvaMALMoraisJJL, et al.Data reduction scheme for measuring GIIc of wood in end-notched flexure (ENF) tests. Hfsg2009; 63: 99–106. DOI: 10.1515/HF.2009.022.
49.
De MouraMFSFCampilhoRDSGGonçalvesJPM. Pure mode II fracture characterization of composite bonded joints. Int J Solid Struct2009; 46: 1589–1595. DOI: 10.1016/j.ijsolstr.2008.12.001.
50.
de MouraMFSF. Interlaminar mode II fracture characterization. Delam Behav of Compos2008; 2008: 310–326.
51.
WangQLiTWangB, et al.Prediction of void growth and fiber volume fraction based on filament winding process mechanics. Compos Struct2020; 246: 112432. DOI: 10.1016/j.compstruct.2020.112432.
52.
ChangYZhouYWangN, et al.Micro-mechanical damage simulation of filament-wound composite with various winding angle under multi-axial loading. Compos Struct2023; 313: 116925. DOI: 10.1016/j.compstruct.2023.116925.
