An experimental method for non-standard off-axis tension tests of unidirectional composites is developed. A new oblique end-tab is designed to eliminate stress concentration and in-plane bending moment induced by off-axis tension loading. Finite element analysis and experiments on Polyetheretherketone (PEEK)/AS4 unidirectional thermoplastic composites (CFRTP) were conducted to evaluate the effectiveness of the proposed testing method. Simulation and test results demonstrate that the use of oblique end-tabs eradicates stress concentration and bending movements. The digital image correlation (DIC) method was used to help investigate the full-field tension/shear coupling deformation response of the off-axis specimen. Test results show significant nonlinear behaviour and inhomogeneous strain distribution under tension/shear combined stresses. A fractographic study was carried out to study the damage mechanisms under a tension/shear combined stress state. Specimens with 30°, 45° and 60° off-axis angles, fail in tension/shear mixed failure mode. Fracture surface morphology indicates that matrix plastic deformation and ductile drawing under tension/shear coupled stress state induced the nonlinear stress-strain response.

An experimental investigation was focused on the failure behavior of unidirectional fiber-reinforced polymers when subjected to combined longitudinal/transverse compression and in-plane shear due to off-axis loading. Block-shaped and end-loaded specimens, spanning ten different fiber orientations (0$°$, 5$°$, 10$°$, 15$°$, 20$°$, 30$°$, 45$°$, 60$°$, 75$°$, and 90$°$ with respect to the loading direction), were loaded to ultimate failure using a dedicated fixture. Different failure modes, including longitudinal compression, in-plane shear, and transverse compression, were identified, along with distinctive characteristics of the corresponding failure envelopes. Four physically based failure theories—Hashin, Camanho, Puck, and LaRC05—were subjected to a comparative analysis. Criteria derived from the concept of the action plane consistently outperformed in describing matrix-dominated failures, providing both qualitative and quantitative predictions of failure stresses and fracture plane orientation. However, for fiber-dominated failures, these theories seem to fall short in providing satisfactory predictions, particularly in accurately describing the influence of shear on fiber compression failure. Although criteria based on fiber-kinking theory can reasonably explain the formation of kink bands, they tend to yield overly conservative results. Recalibrations and minor refinement based on experimental results were implemented, leading to an improved agreement. Finally, the constructive role of off-axis compression tests in characterizing the failure behavior of unidirectional composites is discussed.

This paper presents an experimental investigation on the mechanisms of damage onset and evolution in unidirectional PEEK/AS4 carbon fibre reinforced thermoplastic (CFRTP) composites subjected to off-axis compressive loadings. A test fixture was designed to prevent buckling, splitting, and end collapsing of the specimens during the test. A series of compression tests were conducted with specimens of various off-axis angles. The displacement and strain fields of all specimens during the tests were evaluated by the digital image correlation (DIC) method. In combination with the DIC results, the influence of the off-axis angles on the failure mechanisms and nonlinear stress–strain responses were analysed. The corresponding failure mechanisms were examined by scanning electron microscopy (SEM). The fracture angles of the tested specimens were evaluated and analysed according to Puck’s theory. The off-axis compression failure envelope based on LaRC05 and Hashin criteria was presented and compared to the experimental results. It was shown that the LaRC05 criterion can provide accurate predictions when the off-axis angle is larger than 15°. The complex failure mechanisms were analysed to better understand the effect of ductility of the thermoplastic matrix to the composites. The series of tests provide an experimental failure envelope in combined stress states and can be used for the evaluation of failure theories and the criteria of thermoplastic composites.