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Delamination

Delamination is a mode of failure where a material fractures into layers. A variety of materials, including laminate composites and concrete, can fail by delamination. Processing can create layers in materials, such as steel formed by rolling and plastics and metals from 3D printing which can fail from layer separation. Also, surface coatings, such as paints and films, can delaminate from the coated substrate.

Inspection methods
There are multiple nondestructive testing methods to detect delamination in structures including visual inspection, tap testing (i.e. sounding), ultrasound, radiography, and infrared imaging. Visual inspection is useful for detecting delaminations at the surface and edges of materials. However, a visual inspection may not detect delamination within a material without cutting the material open. Tap testing or sounding involves gently striking the material with a hammer or hard object to find delamination based on the resulting sound. In laminated composites, a clear ringing sound indicates a well bonded material whereas a duller sound indicates the presence of delamination due to the defect dampening the impact. Tap testing is well suited for finding large defects in flat panel composites with a honeycomb core whereas thin laminates may have small defects that are not discernible by sound. Using sound is also subjective and dependent on the inspector's quality of hearing as well as judgement. Any intentional variations in the part may also change the pitch of the produced sound, influencing the inspection. Some of these variations include ply overlaps, ply count change gores, core density change (if used), and geometry. In reinforced concretes intact regions will sound solid whereas delaminated areas will sound hollow. Tap testing large concrete structures is carried about either with a hammer or with a chain dragging device for horizontal surfaces like bridge decks. Bridge decks in cold climate countries which use de-icing salts and chemicals are commonly subject to delamination and as such are typically scheduled for annual inspection by chain-dragging as well as subsequent patch repairs of the surface. == Delamination resistance testing methods ==
Delamination resistance testing methods
Coating delamination tests ASTM provides standards for paint adhesion testing which provides qualitative measures for paints and coatings resistance to delamination from substrates. Tests include cross-cut test, scrape adhesion, and pull-off test. Interlaminar fracture toughness testing Fracture toughness is a material property that describes resistance to fracture and delamination. It is denoted by critical stress intensity factor K_c or critical strain energy release rate G_c. For unidirectional fiber reinforced polymer laminate composites, ASTM provides standards for determining mode I fracture toughness G_{IC} and mode II fracture toughness G_{IIC} of the interlaminar matrix. During the tests load P and displacement \delta is recorded for analysis to determine the strain energy release rate from the compliance method. G in terms of compliance is given by{{Equation|1=G = \frac{P^2}{2B}\frac{dC}{da}|2=1}} where dC is the change in compliance C (ratio of \delta /P), B is the thickness of the specimen, and da is the change in crack length. Mode I interlaminar fracture toughness ASTM D5528 specifies the use of the double cantilever beam (DCB) specimen geometry for determining mode I interlaminar fracture toughness. Multiple test architectures have been proposed for use in measuring interlaminar shear strength, including the short beam shear test, Iosipescu test, rail shear test, and asymmetrical four-point bending test. The goal of each of these tests is to maximize the ratio of shear stress to tensile stress exhibited in the sample, promoting failure via delamination of the fiber-matrix interface instead of through fiber tension or buckling. The orthotropic symmetry of fiber composite materials makes a state of pure shear stress difficult to obtain in sample testing; thin cylindrical specimens can be used but are costly to manufacture. Sample geometries are thus chosen for ease of machining and optimization of the stress state when loaded. In addition to manufactured composites such as glass fiber-reinforced polymers, interlaminar shear strength is an important property in natural materials such as wood. The long, thin shape of floorboards, for example, may promote deformation that leads to vibrations. Asymmetric four-point bending Asymmetric four-point bending (AFPB) may be chosen to measure interlaminar shear strength over other procedures for a variety of reasons, including specimen machinability, test reproducibility, and equipment availability. For example, short-beam shear samples are constrained to a specific length-thickness ratio to prevent bending failure, and the shear stress distribution across the specimen is non-uniform, both of which contribute to a lack of reproducibility. Rectangular samples can be used with or without notches machined at the center; the addition of notches helps to control the position of the failure along the length of the sample, but improper or nonsymmetrical machining can result in the addition of undesired normal stresses which reduce the measured strength. The sample is then loaded in compression in its test fixture, with loading applied directly to the sample from 4 loading pins arranged in a parallelogram-like configuration. The load applied from the test fixture is transferred unevenly to the top two pins; the ratio of the inner pin load P and outer pin load Q is defined as the loading factor \lambda, such that :\frac{P}{Q} = \frac{S_2}{S_1} = \lambda, where S_1 and S_2 are the lengths from the inner pin to the applied point load and from the outer pin to the applied point load, respectively. The normal stress in the sample \sigma_{xx} is maximized at the locations of the inner pins, and is equivalent to :\sigma_{xx} = \frac{6(\lambda-1)FL}{(1+\lambda^2)bt}, where F is the total applied load on the sample, L is the sample length, b is the sample width (into the page as seen in a 2D free-body diagram), and t is the sample thickness. The shear stress \sigma_{xz} in the sample is maximized in between the inner span of the pins and is given by :\sigma_{xz} = \frac{3(1- \lambda)F}{2(1+ \lambda)bt}. The ratio of normal to shear stress in the sample C is given by :C = \frac{\sigma_{xx}}{\sigma_{xz}} = \frac{4L}{(1+\lambda)t}. This ratio is dependent both on the loading factor of the sample and its length-thickness ratio; both of these quantities are important in determining the mode of failure of the sample in testing. == References ==
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