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We present, for the first time, an experimental investigation of internal strain monitoring in thermoplastic composites subjected to quasi-static indentation and low-velocity impact using embedded fiber Bragg gratings (FBGs). The goal is to highlight the interest and limitations of the in-core instrumentation of glass fiber-reinforced polypropylene laminates subjected to these two classical loading conditions. We propose an instrumentation strategy utilizing FBGs that is expected to provide a reliable set of internal strain values and strain rates, which can be used for the analysis of the damage behavior and the validation of a numerical mesoscale model of laminates. Based on a specific sensor insertion procedure, monitoring techniques and optical observations, we show how the applied methodology alleviates major issues, such as determining the in-plane and through-thickness position of the embedded FBGs, their influence on the structural integrity or the interpretation of the reflected optical signal.

Matrix behavior is expected to widely influence the impact response of composites, but detailed conclusions in the case of thermoplastic laminates are still needed. In this paper, we investigated the effect of using either ductile homopolymer PP or less-ductile impact copolymer PP matrices on the low-velocity impact responses of continuous glass fiber-reinforced polypropylene (PP) laminate. These PP types represent two variants in the same family of thermoplastic matrix. A thorough experimental campaign was first performed to provide the tensile properties (for PP and glass/PP) and fracture toughness (Mode-I and Mode-II, glass/PP only) of the employed materials. Then, low-velocity impact tests where the energy levels are ranging from 12 to 30 J were performed. Using ductile PP in glass/PP laminates reduces the energy dissipated during impact as well as the impact damage area. The effect of selected stacking sequences on the resistance to impact was also studied as a way to reveal the difference between ductile and less-ductile glass/PP. Stacking sequence with thin plies shows better impact properties than other sequences regardless of the matrix ductility, which can be explained by micromechanics for both grades of material. Finally, as quasi-static indentation (QSI) is usually used to quickly access the resistance of laminates towards out-of-plane impact, we systematically compared our impact results with QSI results. We found that the prospective use of QSI in forecasting impact properties and damage is very limited in glass/PP composite due to strain-rate sensitivity.

Measuring parameters related to each damage mode of composites subjected to impact is very challenging because of the complex damage phenomenology. Here, we developed an experimental methodology for evaluating the micro-scale fracture characteristics of two principal damage modes, i.e., transverse crack and delamination, and providing the corresponding fracture toughness. We demonstrated the capability of the method by comparing and providing additional insights about two materials, namely homopolymer-based (ductile) and copolymer-based (less-ductile) glass/polypropylene thermoplastic composites. We found that (i) transverse crack behavior of both composites is similar as indicated by a small difference in their fracture toughness, (ii) delamination growth in copolymer-based composites is slower than in homopolymer-based composites, (iii) the fibrillation induced by rubber particles in copolymer-based composites is responsible for decelerating the delamination growth and improving its fracture toughness during delamination. This method is deemed useful and quick for determining the micro-scale fracture behavior of composite laminates under impact in order to support the material selection process.

We investigate the influence of process-induced shrinkage and subsequent annealing on the thermomechanical behavior of unidirectional laminates made of continuous glass fiber-reinforced polypropylene (GFPP). We use two different industrial lamination processes: static hot-press (SHP), and double-belt press (DBP) that are characterized by different cooling rates and pressure levels and most importantly, by the use of a closed mold in the case of SHP manufacturing. We measure the longitudinal and transverse shrinkage during the manufacturing and annealing processes using embedded fiber Bragg gratings (FBGs). The SHP molding reveals much lower induced shrinkage in GFPP as compared to the DBP process, although the relatively slow cooling should promote a higher degree of crystallization. We ascribe this to the constraining effect of the metallic mold used with the SHP process. The poor thermal conductivity of the mold is also responsible for a layer-like crystal microstructure in the GFPP matrix, causing a specific relaxation effect during the post-process heating treatment. Annealing generates additional shrinkage that is due to an increased degree of crystallinity and to the partial relaxation of residual stresses. However, the thermal expansion properties remain impacted by the process-induced strain state of the GFPP laminates and are still process-dependent after annealing.

Fiber-reinforced composites with improved dissipation of energy during impact loading have recently been developed based on a polypropylene copolymer commonly called impact polypropylene (IPP). Composites made of IPP reinforced with glass fibers (GF) are particularly attractive to the automotive industry due to their low cost and good impact resistance. In such composites, the cooling rate varies depending on processing techniques and manufacturing choices. Here, we study the effects of the cooling rate of GF-IPP composites on shear behavior, which is critical in impact applications, using [ ± 45 ] s monotonic and cyclic (load/unload) tensile specimens. The specimens were manufactured under a wide range of cooling rates (3 °C/min, 22 °C/min, 500–1000 °C/min). Mainly dominated by the properties of the matrix, the global shear behavior of GF-IPP composites differed considerably with respect to the cooling rate. However, the performance of the fiber-matrix interface (chemically modified) appeared to be unaffected by the range of cooling rates used in this study. We found that the cooling rate has a minor effect on the rate of damage accumulation, while it strongly modifies the shear-activated rate-dependant viscoelastic behavior.

Impact copolymer polypropylene (IPP), a blend of isotactic polypropylene and ethylene-propylene rubber, and its continuous glass fiber composite form (glass fiber-reinforced impact polypropylene, GFIPP) are promising materials for impact-prone automotive structures. However, basic mechanical properties and corresponding damage of IPP and GFIPP at different rates, which are of keen interest in the material development stage and numerical tool validation, have not been reported. Here, we applied monotonic and cyclic tensile loads to IPP and GFIPP at different strain rates (0.001/s, 0.01/s and 0.1/s) to study the mechanical properties, failure modes and the damage parameters. We used monotonic and cyclic tests to obtain mechanical properties and define damage parameters, respectively. We also used scanning electron microscopy (SEM) images to visualize the failure mode. We found that IPP generally exhibits brittle fracture (with relatively low failure strain of 2.69–3.74%) and viscoelastic-viscoplastic behavior. GFIPP [90]8 is generally insensitive to strain rate due to localized damage initiation mostly in the matrix phase leading to catastrophic transverse failure. In contrast, GFIPP [±45]s is sensitive to the strain rate as indicated by the change in shear modulus, shear strength and failure mode.