Abstract
Due to its good mechanical performances and design flexibility, long glass fiber-reinforced polypropylene (hereinafter referred to as LGFRP) composite has been increasingly used in the automotive industry, in which the LGFRP components are likely to sustain different strain rates loading during a crash event. The objectives of this study are to investigate the correlations between the LGFRP and strain rates 10−3 s−1 to 50 s−1, and the corresponding failure modes of LGFRP. Therefore, tensile and compression tests are conducted at different strain rates and the corresponding microstructures of the specimens are investigated with scanning electron microscope. The experimental results show that the failure strain and ultimate strength increase as increasing strain rate. The elastic modulus is sensitive to strain rate in tensile tests, but less sensitive to strain rate in compression tests. The main failure modes of the specimens are the matrix crack and fiber pull-out. The defects such as bubbles, shrinkage cavities, or dry fibers of the specimens play important roles in the initiation and propagation of cracks during the tensile and compression tests.
Introduction
Composites as novel materials have been increasingly used in aerospace, transportation, defense, sport, medical equipments and consumer products because of their advantages of light weight, high strength/weight, stiffness/weight, good vibration attenuation effect, design flexibility act.
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As one class of typical composites, glass fiber-reinforced polypropylene (GFRP) has been widely adopted in automobile industry for lightweight design. A composite bus was developed using woven glass/polypropylene composites by Tillotson Pearson Inc., which led to over 30% weight reduction compared with conventional metallic bus.
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Glass fibers/polypropylene is one kind of GFRP, which offers the potential for rapid manufacturing with low cycle times that allows for medium to high volume production. Moreover, glass fibers and polypropylene can be recycled.
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Therefore, glass fibers/polypropylene has been extensively adopted in vehicle components, such as roof door, body panel, frame segment, floor segments, battery access door, and seating systems with a weight reduction ranging from 40% to 60%, whilst maintaining the same or even better performance compared to conventional metallic components.4–8 Some of these components are likely to sustain rate loading during a crash event. Moreover, accurate material model under different strain rates (
The effect of strain rate on the mechanical properties of GFRP was investigated during several previous studies. The strength, fracture strain, and the impact strength of the GFRP increase with increasing strain rate, which is confirmed by literatures.10,11 Reis et al.
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reported dynamic tensile tests for GFRP and observed that the mechanical properties of the GFRP show a strain-rate dependency. Taniguchi et al.
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observed that the strength of GFRP made of T-glass increases with increasing strain rate. Papadakis et al.12,13 investigated the effect of strain rate on the tensile and shear properties of a continuous glass fibers and polypropylene at various crosshead speeds. They observed that the Young’s modulus increases with increasing loading rate whilst the ultimate strength (
Published papers on the mechanisms of composite failure at low and high strain rates are rarely seen. Yuan et al. 17 studied impact compressive failure of GFRP unidirectional composites. The research results have shown that GFRP exhibited ductile failure for lower fiber volume fractions, but brittle failure for higher fiber volume fractions. As the temperature increased, the failure mode changed from kinking to micro-buckling. Experiments showed that the strain rate has a strong effect on the compressive strength. Suvorova 18 pointed out that changing in loading rates affects the final failure modes of composite structures. Wang and Cho 19 investigated the failure modes of satin weave E-glass/epoxy composite laminates. The experimental results show that the failure mode changes from splitting follows by fiber kink buckling to predominantly de-lamination and shear fracture as strain rates increases from quasi-static to high strain rates. Zhou and Zhang 20 researched the failure behavior of CFRP composites at high strain rates. The research shows that the main way of the dynamic compressive failures in the normal direction is shear failure due to the brittle fracture of the fiber. The results also indicate interfacial crack and de-lamination can be produced in the in-plane direction. Zhou et al. 21 investigated the dynamic mechanical behavior of fiber-reinforced polymer composites embedded with ZnO whiskers. The investigation shows that the tensile properties of the composites are dominated by pull-out and fracture of fiber bundles. So far, according to the literatures reviewed by the authors, there is not much information that is available on the failure of long GFRP (LGFRP) under different strain rates.
Although some investigations on strain-rate-dependent behavior and failure modes of composites are reported in the above literatures, most of the above studies focus on thermosetting materials and few investigations focus on glass fibers/polypropylene composite, especially on LGFRP. LGFRP, as a new composite with advantages of favorable mechanical and shaping properties applied in vehicle industry, is important to investigate the effect of strain rate on the mechanical properties of LGFRP for vehicle design and crashworthiness assessment. Furthermore, the research of failure modes related to
Experimental setup
Material and fabrication process
The LGFRP is manufactured by air laying web technology in this paper. In the air lay process, the fibers are suspended in an air stream and then blown or forced into a continuously moving belt where the web is formed. So air laying web technology can be used to produce the three-dimensional structure of fiber mat, in which the fiber arrangement is non-direction as shown in Figure 1(a). So the strength ratio of longitudinal and transverse for the product made of the fiber mat can reach 1:1. The LGFRP used in this study is a commingled long E-glass fiber and polypropylene fiber composite, balanced 1:1 combination mat with a nominal 20% E-glass fiber volume fraction (Table 1). Figure 1 shows that the fiber mat of LGFRP, in which the specification of the fiber is 900 dtex, 40 to 50 mm length. In Figure 1(b), the white fibers are the long E-glass fibers and the blank fibers are the polypropylene fibers.
Inner structures (a, magnification is 288) and combination mat (b, magnification is 30). PP: polypropylene. The materials composition of LGFRP.
The preparation process of the experimental materials is as follows. Pre-consolidated combination mat is stacked ply-by-ply in an infrared oven, preheated at a temperature of 200℃. And the time for heat preservation is 2 min. The stack is then rapidly transferred to a preheated tool (70–80℃) which is installed in a stroking servo-hydraulic press. The tool is closed and pressure holding time is 30 s. Then, the composite plates and cylindrical specimens are obtained.
Specimens and test procedure
The dumbbell tensile specimens are cut from the flat planes, as shown in Figure 2. The thickness and density are Long glass fiber/polypropylene tensile specimen shape and dimension (measured in millimeters) (a) and typical tensile test specimen (b). Compression test specimen shape and dimension (a) and typical compression test specimen (b).

Both quasi-static tests and dynamic tensile tests are conducted in a fatigue testing machine (MTS 647 Hydraulic Wedge Grip). The speed v of clamp is set according to the strain rate. In order to prevent the fracture of specimens in chuck position in tensile tests, the clamping parts of the specimens are reinforced by aluminum alloy plates with 1 mm thickness. The displacement response of tensile specimen is measured by an extensometer with 20 mm gauge length. To alleviate the friction between the compression specimen and fixture, butter is coated on both ends of the specimen. The tests in the same conditions are repeated five or more than five times to obtain the reliable experimental data. And then a revised stress–stain curve is obtained by taking the average value of the three similar stress–strain curves.
Phenom desktop microscope with the largest magnification 24,000 times is used to investigate failure mechanisms of the fractured composite specimens. For optical microscopic analysis, sample sections are cut from the failure region of the fractured specimens.
Results and discussion
Tensile experiments
Strain–stress curves
After processing the tensile experimental data, the stress–strain curves of LGFRP at different strain rates are obtained as shown in Figure 4. Under strain rates Typical tensile stress–strain curves for LGFRP at different strain rates 0.001 s−1 to 0.1 s−1 (a) and 1 s−1 to 50 s−1 (b).
Tensile properties for LGFRP at different strain rates.
Failure modes analysis
Under strain rates Failure modes for tensile specimens.
In the preparation of the experimental specimens, the PP fibers are plasticized to viscous state and are forced into the pores among the glass fibers by outer pressure. Then, the specimens are cooled to room temperature. In this process, some defects (as shown in Figure 6(c②)) such as bubbles, shrinkage cavities, or dry fibers may emerge. These defects may have a great influence on the properties of the material.
Schematic representation of tensile stress–strain curve (a), possible tensile micro-failure modes (b), and optical micrographs for tensile specimens (c). PP: polypropylene.
Based on the experimental stress–strain curves as shown in Figure 4, all the curves can be divided into three phases as shown in Figure 6(a), elastic phase indicated by I, initiation of fracture phase indicated by II, and propagation of fracture phase indicated by III. Therefore, the schematic representation of the three phases is used to analysis the failure process as shown in Figure 6(b). In the first phase, the strain is very small and the stress is linear with strain. The inner defects are no change due to the low stress. In the second phase, the elastic deformation energy increase with the increasing load. There is no evident damage in the specimens. Nevertheless, in microstructure analysis, the defects may grow and matrix cracks, even local de-bonding (Figure 6(c②)) may emerge. Due to the uneven of material property and stress distribution, the defects always firstly generate in the weakened area where stress concentration is greater. Then, the defects may generate in the other area due to “synergistic effect,” which indicates that stress concentration area transfers caused by the stress redistributes. In the third phase, when the load exceeds the critical load of crack propagation, the local defects converge, and cracks propagate at the same time. Then, the macroscopic damage can be seen, including matrix cracking, fiber or fiber bundle pull-out, and fiber breakage. As shown in Figure 6(a), the stress–strain curves decline rapidly when the load exceeds the critical load at high strain rate. Thus, the crack mechanism of specimens is brittle crack. The cause may lie in that the crack converge and propagate very rapidly.
Now, the authors discuss the failure modes (pull-out or rupture) of glass fibers. The factors influences failure modes of glass fibers include the fiber/matrix interfacial strength, the existing form of the fibers in the matrix (fiber axial and the loading direction is parallel or at an angle, fibers hook together), the fiber dispersion, and uniformity. It can be made the following analysis. The tensile breaking force Fb of glass fiber can be calculated by equation (1)
The pull-out force of the fiber Fp can be calculated by equation (2)
Setting the
Therefore, the glass fiber will be broken when the embedded length of the fiber is greater than lc, or the fiber will be pulled out. Schematic representation of tensile fiber. Optical micrographs for tensile specimens: pulled out fiber (a, magnification is 6000), fracture surface (b, magnification is 292), hollow in the matrix (c, magnification is 2300), and glass fiber (d, magnification is 1300). PP: polypropylene.

Optical micrographs of the damage region in the fractured tensile specimens are shown in Figure 8. The smooth hollow in the matrix left by the fiber pull-out can be observed shown in Figure 8(c). The end face of the pulled out fibers are flat shown in Figure 8(d), but the fibers with flat end face are not necessarily pulled out, may be fractured (when the embedded length of the fiber is greater than lc). Figure 8(d) shows that the rugged end face of the fibers can be concluded that the failure mode of the fibers is fracture.
Compression experiments
Strain–stress curves
Typical compression stress–strain plots under different strain rates are shown in Figure 9. Under the strain rates from Typical compression stress–strain curves for LGFRP at different strain rates 0.001 s−1 to 0.1 s−1 (a) and 1 s−1 to 50 s−1 (b). Compression properties for LGFRP at different strain rates.
Failure modes analysis
The different failure modes of compression specimens are shown in Figure 10. Under strain rates Failure modes for compression specimens.
Just like the tensile stress–strain curves, the compressive stress–strain curves is composite of three segments, as shown in Figure 11, which indicates the three phase in the process of compression, namely elastic phase indicated by I, densification and initiation of fracture phase indicated by II, and propagation of fracture phase indicated by III. For all the three phases, the stress is approximately linear with strain. In the first phase, the glass fiber, matrix, and defects change little, and deformation of the specimen can recover (as shown in Figure 11(b), I phase) when unloading. In the densification stage, although partial defects such as shrinkage cavity are compressed, the specimens are not completely densified. At the same time, the matrix and glass fiber around defects begin to deform. The differences of Poisson’s ratio and the elastic modulus between glass fiber and matrix cause stress concentration, which leads to the initial cracks. This is the second phase, which is shown in Figure 11(b) II phase. In the third phase, when the load exceeds the critical load of crack propagation, the disperse defects continue expanding, meanwhile the adjacent cracks converge. Then, macroscopic damage such as matrix fracture or fiber pull-out can be seen, which can lead to the final failure of the specimens. The failure mode of the compression specimens is brittle fracture, which is the same as that of the tensile specimens. In other words, the convergence and propagation of cracks are very rapidly in the third phase.
Schematic representation of compression stress–strain curve (a) and possible compression micro-failure modes (b).
Although cracks take place in many places of composite specimens on the microlevel, there are usually only several cracks on the macro level. Through matching two sections, the crack initiation zone and extension direction can be determined. When the load is applied to composite material, the initiation and extension of the crack will be stopped by fibers, and the cracks tend to develop along the interface between the fiber and matrix, which leads to the formation of many bifurcate micro cracks. Therefore, the initiation zone of damage exists in the crack initiation zone. The information about effect of defects on crack initiation can be provided by the scanning electric microscope observation. Finally, through the analysis of the macro to micro and according to the previously discussed basic failure modes, the main failure mode with matrix cracking, fibers, or fiber bundle pull-out of compression specimens can be determined.
Comparison and analysis the results of tensile and compression experiments
The ultimate strengths and failure strains of the tensile and compression specimens are all very sensitive to strain rate as shown in earlier subsections. The elastic modulus of tensile specimens decrease from 6522.479 MPa to 2100 MPa with increasing strain rate between
Conclusion
In the present work, the properties and failure modes of LGFRP composites were investigated for a range of strain rate from
Footnotes
Conflict of Interest
None declared.
Funding
This work is supported by Open Research Fund Program of the State Key Laboratory of Advanced Design and Manufacturing for Vehicle Body (Grant No. 31115014) and the National Natural Science Foundation of China (Grant No. 51405150).
