Rupture by impact-induced fatigue of a copper foil strip embedded in a multifunctional composite material

Multifunctional composite materials are highly sought-after by the aerospace and aeronautical industry but their performance depends on their ability to sustain various forms of damages, in particular damages due to repeated impacts. In this work we studied the mechanical behavior of a layered glass-epoxy composite with copper inserts subjected to fatigue under repeated impacts with different energy levels. Damage evolution as a function of impact energy was carefully monitored in order to determine the effect of the copper inserts on mechanical characteristics of the multifunctional composite, such as endurance and life. Results of repeated impact tests show that electric current interruption in the copper inserts occurs prior to the total perforation of the composite material, and after about 75% of the total number of impacts to failure. This is the case for the three energy levels considered in this study, {E}_i = 2, 3 and 4 Joules. The epoxy resin was dissolved chemically in order to preserve the mechanical structure of the damaged copper inserts and the composite fibers for further inspection and analysis. Scanning electron microscopy (SEM) of the fractured copper inserts revealed interesting information on the nature of the damage, including information on plastic deformation, strain hardening, cracking mode, temperature increase during the impacts, and most importantly the glass fibers and their roles during the impact-fatigue tests.