ABSTRACT
The focus of this research is an investigation on the fatigue behaviour of unidirectional 3D-printed continuous carbon fibre-reinforced polymer (CFRP) tension straps with a polyamide matrix (PA12). Conventionally produced tension straps are becoming established components in the mechanical as well as the civil engineering sector, e.g., as rigging systems for sailing boats and cranes and-recently introduced-as network arch bridge hangers. All these structures are subjected to high fatigue loads, and although it is commonly reported that carbon fibre-reinforced polymers show excellent fatigue resistance, there is limited understanding of the behaviour of CFRP loop elements under such loads, especially in combination with fretting at the attachment points. Research on this topic was performed at Empa in the past decade on thermoset CFRP straps, but never before with 3D-printed continuous CFRP straps with a thermoplastic matrix. This paper examines an additive manufacturing and post-consolidation method for producing the straps and presents initial results on their fatigue performance, which show that the fatigue endurance limit of the investigated 3D-printed and post-consolidated CFRP strap design is acceptable, when compared to steel tendons. However, it is still 20% lower than conventionally produced CFRP straps using out-of-autoclave unidirectional carbon fibre prepregs. The reasons for these findings and potential future improvements are discussed.
ABSTRACT
The fretting fatigue performance of laminated, unidirectional (UD), pin-loaded, carbon fibre-reinforced polymer (CFRP) straps that can be used as bridge hanger cables was investigated at a sustained service temperature of 60 °C. The aim of this paper is to elucidate the influence of the slightly elevated service temperature on the tensile fatigue performance of CFRP straps. First, steady state thermal tests at ambient temperature and at 60 °C are presented, in order to establish the behaviour of the straps at these temperatures. These results indicated that the static tensile performance of the straps is not affected by the increase in temperature. Subsequently, nine upper stress levels (USLs) between 650 and 1400 MPa were chosen in order to establish the S-N curve at 60 °C (frequency 10 Hz; R = 0.1) and a comparison with an existing S-N curve at ambient temperature was made. In general, the straps fatigue limit was slightly decreased by temperature, up to 750 MPa USL, while, for the higher USLs, the straps performed slightly better as compared with the S-N curve at ambient temperature.
ABSTRACT
Steel cables and suspenders in bridges are at high risk of corrosion-fatigue and in some cases of fretting-fatigue in their anchorages. These factors greatly limit the service stresses of a specific cable system and involve expensive protection measures. In order to investigate the above limitations, the fretting fatigue behaviour of pin-loaded carbon fibre reinforced polymer (CFRP) straps was studied as models for corrosion-resistant bridge suspenders. Two types of straps were tested: small model straps with a sacrificial CFRP ply and large full-scale straps. In a first phase, five fully laminated and carbon pin-loaded CFRP model straps were subjected to an ultimate tensile strength test. Thereafter, and in order to assess their durability, 20 model straps were subjected to a fretting fatigue test, which was successfully passed by 4 straps. An S-N curve was generated for a load ratio of 0.1 and a frequency of 10 Hz. In a second phase, one full-scale strap was tested for its ultimate tensile strength and two full-scale straps were fatigue-tested. The influence of fretting fatigue loading on the residual mechanical properties of the straps was also assessed, and although fretting fatigue represented an important limitation for laminated CFRP straps, it could be shown that the investigated CFRP tension members can compete with the well-established steel suspenders.
