A statistical approach to predict fatigue failure of leaf springs manufactured with nanotube incorporated epoxy‐woven glass fiber composites

Abstract In this study, a statistical approach was developed to predict fatigue failure of laminated composite leaf springs prepared with carbon nanotube (CNT) filled epoxy/woven glass fibers. Electrical resistance change method and the Weibull analysis were adopted to develop a statistical approach. The electrical conductivity for successful application of health monitoring of leaf springs was achieved by dispersing 0.4 wt% of CNTs into epoxy resin. In‐situ monitoring of damage in composite leaf springs during fatigue tests applied as cyclic flexural deflection was carried out at nine different displacement ratios. The critical fatigue cycle and the corresponding change in electrical resistance were determined at each displacement ratio. Then, the critical electrical resistance change to cyclic fatigue was found 0.15% with 95% reliability by the Weibull analysis. The average fatigue life and the average strength loss corresponding to the 0.15% resistance change ratio were found to be 48.33% and 9.88%, respectively. The reported statistical concept based on the monitoring of change in electrical resistance during deflection can be successfully employed as a useful tool to predict safety limits of composite structures subjected to fatigue loading, especially in aerospace industry.