Examining infrared thermography based approaches to rapid fatigue characterization of additively manufactured compression molded short fiber thermoplastic composites

P. Pathak; S. Gururaja; V. Kumar; D. Nuttall; A. Mahmoudi; M. M. Khonsari; U. Vaidya

doi:10.1016/j.compstruct.2024.118610

Examining infrared thermography based approaches to rapid fatigue characterization of additively manufactured compression molded short fiber thermoplastic composites

P. Pathak, S. Gururaja, V. Kumar, D. Nuttall, A. Mahmoudi, M. M. Khonsari, U. Vaidya

Composites Innovation

Research output: Contribution to journal › Article › peer-review

Abstract

A novel additive manufacturing (AM) methodology combined with a compression molding (CM) process has been previously developed to optimize the microstructure of short fiber thermoplastic (SFTs) composites with higher fiber alignment and lower porosity, yielding superior stiffness, strength, and structural integrity. The current work examines the efficacy of the ‘passive’ infrared thermography (IRT) techniques for rapid fatigue characterization of SFTs that use the surface temperature evolution during cyclic loading due to self-heating as a fatigue indicator. A comparison of fatigue limits obtained from traditional stress-life (SN) (≈53.1%σ_uts) and IRT (≈54.1%σ_uts) shows a close match. However, the SN curve required 18 specimens and two weeks of continuous cyclic testing, while IRT used three specimens with 5 h of testing. Thus, the IRT approach provides an accelerated testing framework for rapidly estimating the fatigue limit. Additionally, existing phenomenological approaches to IRT fatigue characterization have been examined.

Original language	English
Article number	118610
Journal	Composite Structures
Volume	351
DOIs	https://doi.org/10.1016/j.compstruct.2024.118610
State	Published - Jan 1 2025

Funding

The research is partly supported by the US Department of Energy (DOE), Office of Energy Efficiency and Renewable Energy, Advanced Manufacturing Office, under contract DE-AC05-00OR22725 with UT-Battelle LLC. A.M. and M. K. acknowledge the support US National Science Foundation, grant number 2243755. The authors acknowledge Mr. Nithinkumar Manoharan, a graduate student of the Department of Aerospace Engineering, Auburn University, for his support during specimen fabrication and initial fatigue testing. A part of the paper was presented at the 2023 SEM Annual Conference held in Orlando, FL, USA, in June 2023. The research is partly supported by the US Department of Energy (DOE), Office of Energy Efficiency and Renewable Energy, Advanced Manufacturing Office , under contract DE-AC05-00OR22725 with UT-Battelle LLC. The authors acknowledge Mr. Nithinkumar Manoharan, a graduate student of the Department of Aerospace Engineering, Auburn University, for his support during specimen fabrication and initial fatigue testing. A part of the paper was presented at the 2023 SEM Annual Conference held in Orlando, FL, USA, in June 2023.

Funders	Funder number
Department of Aerospace Engineering
Office of Energy Efficiency and Renewable Energy
U.S. Department of Energy
Auburn University
UT-Battelle
Advanced Manufacturing Office	DE-AC05-00OR22725
Advanced Manufacturing Office
National Science Foundation	2243755
National Science Foundation

Keywords

AM-CM
Fatigue
Infrared thermography
SFTs
Self-heating

UN SDGs

This output contributes to the following UN Sustainable Development Goals (SDGs)

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10.1016/j.compstruct.2024.118610

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title = "Examining infrared thermography based approaches to rapid fatigue characterization of additively manufactured compression molded short fiber thermoplastic composites",

abstract = "A novel additive manufacturing (AM) methodology combined with a compression molding (CM) process has been previously developed to optimize the microstructure of short fiber thermoplastic (SFTs) composites with higher fiber alignment and lower porosity, yielding superior stiffness, strength, and structural integrity. The current work examines the efficacy of the {\textquoteleft}passive{\textquoteright} infrared thermography (IRT) techniques for rapid fatigue characterization of SFTs that use the surface temperature evolution during cyclic loading due to self-heating as a fatigue indicator. A comparison of fatigue limits obtained from traditional stress-life (SN) (≈53.1%σuts) and IRT (≈54.1%σuts) shows a close match. However, the SN curve required 18 specimens and two weeks of continuous cyclic testing, while IRT used three specimens with 5 h of testing. Thus, the IRT approach provides an accelerated testing framework for rapidly estimating the fatigue limit. Additionally, existing phenomenological approaches to IRT fatigue characterization have been examined.",

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AU - Khonsari, M. M.

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AB - A novel additive manufacturing (AM) methodology combined with a compression molding (CM) process has been previously developed to optimize the microstructure of short fiber thermoplastic (SFTs) composites with higher fiber alignment and lower porosity, yielding superior stiffness, strength, and structural integrity. The current work examines the efficacy of the ‘passive’ infrared thermography (IRT) techniques for rapid fatigue characterization of SFTs that use the surface temperature evolution during cyclic loading due to self-heating as a fatigue indicator. A comparison of fatigue limits obtained from traditional stress-life (SN) (≈53.1%σuts) and IRT (≈54.1%σuts) shows a close match. However, the SN curve required 18 specimens and two weeks of continuous cyclic testing, while IRT used three specimens with 5 h of testing. Thus, the IRT approach provides an accelerated testing framework for rapidly estimating the fatigue limit. Additionally, existing phenomenological approaches to IRT fatigue characterization have been examined.

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Examining infrared thermography based approaches to rapid fatigue characterization of additively manufactured compression molded short fiber thermoplastic composites

Abstract

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Keywords

UN SDGs

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