The present study is a comprehensive experimental investigation of the uncertainties in the mechanical response of short fibre-reinforced composites. The reference material investigated is a short glass fibre-reinforced phenolic resin matrix material, manufactured in a thermoset injection-moulding process. The mechanical material response was investigated in experiments on three different scales, considering ISO-size, miniature, and micro tensile samples. Further to the tensile experiments, compressive and shear tests were performed on macroscopic samples. Experiments on breadboard samples featuring more complex stress and deformation states complete the study. The injection-moulding process was found to control the basic fibre orientation. However, the nominal local fibre orientation distribution is superimposed with a pronounced local uncertainty. This microstructural uncertainty strongly affects the uncertainty in the local mechanical properties as well as variations between samples taken from identical positions in different but nominally identical plates.

This study focuses on the scatter in the mechanical properties in short fibre composites caused by uncertain fibre orientations. To interrelate the microstructural geometric and topological uncertainty with the material uncertainty on the macroscopic level, a numerical approach is utilized. Considering short fibre reinforced microstructures statistically described in terms of the probability distributions for the main stochastic variables such as fibre orientation, length, and density, statistically equivalent microstructural geometric models are generated using random number generation. The mechanical response of these microstructures is analysed in finite element analyses under different independent loading situations. The large-scale representative volume elements are subdivided for the evaluation into non independent stochastic volume elements. Like this the surrounding microstructure is included in the boundary conditions. A numerical homogenization analysis is applied on the statistic volume elements to evaluate effective macroscopic material parameters and their probability distributions. The results are correlated with the uncertainty of the input parameters.

The present study is concerned with an experimental study into the effect of superimposed creep deformation, varying local fiber orientation distributions, and more complex multiaxial stress states on the fatigue of short fiber reinforced thermoplastics. The cross-interaction of these effects is a relevant feature in all fields of applications of short fiber composites since molding related variations of the local fiber orientation states cannot be avoided for injection molded structures. Long term loading will result in a combined occurrence of fatigue and creep and thus an interaction of the related effects. The study is based on a short glass fiber reinforced polyamide 66 as reference material which is a common material grade in many automotive applications. A basic characterization is performed by means of tensile and DMA experiments. Subsequently, creep and creep fatigue experiments are performed at ambient and elevated temperatures. In order to include the effects of locally varying fiber orientation situations and locally multiaxial loading situations, the coupon experiments are complemented by experiments on breadboard specimens featuring notches, holes, and structural component related external geometries. Superimposed creep deformation might accelerate fatigue failure, however, for notched specimens might also result in an increased fatigue lifetime due to creep-induced stress relief at the notch roots. The results reveal that care has to be taken when transferring the results on idealized coupon specimens to generalized, realistic problems. The results also serve as a development and validation data base for a continuum damage mechanics material model presented in an oncoming contribution.