"Experimental and Theoretical Fracture Analysis of RIFT Manufactured Ca" by Daniel Joseph Longo

Date of Award

5-2025

Document Type

Thesis

Degree Name

Master of Science (MS)

Department

Aerospace, Physics, and Space Sciences

First Advisor

Mirmilad Mirsayar, Ph.D.

Second Advisor

Soheil Saeidi, Ph.D.

Third Advisor

Ratneshwar Jha, Ph.D.

Abstract

This thesis investigates the fracture behavior of unidirectional carbon fiber-vinyl ester (CFVE) laminates manufactured using the Resin Infusion with Flexible Tooling (RIFT) process, a cost-effective alternative to autoclave-based fabrication methods. Composite materials like CFVE are increasingly adopted in high-performance applications due to their high strength-to-weight ratio and corrosion resistance; however, their anisotropic nature presents challenges in predicting crack initiation and propagation. To address this, a comprehensive approach combining experimental testing, finite element modeling (FEM), and classical fracture mechanics was employed. Orthotropic mechanical properties were first determined through tensile and shear tests, providing critical properties for FEM simulations. A series of FEM analyses were conducted to calculate Mode I and Mode II stress intensity factors (SIFs) for various fiber orientations and crack angles. These models guided the design of fracture experiments, which validated the predicted fracture toughness values and revealed a strong correlation with material orientation and crack path behavior. A nearly pure Mode II fracture case was also identified and confirmed numerically and experimentally. The results demonstrate that LEFM, supported by FEM and tailored experiments, can effectively characterize fractures in CFVE laminates. This work enhances the understanding of mixed-mode fracture mechanisms in composite materials and supports the broader application of RIFT-fabricated laminates in structurally demanding environments.

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