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<p>Polymer coating and composite wrapping are extensively employed in pressure vessel structures due to their lightweight nature and superior corrosion resistance compared to full-metal vessels. However, conventional polymer coatings exhibit limited fracture toughness, leading to premature failure and increased maintenance costs. This study introduces an innovative material (IM) overlay, fabricated using a multilayered combination of wood-reinforced PLA (M1), carbon-reinforced PLA (M2), and ceramic-reinforced PLA (M3), arranged in a sequential M1–M2–M3 pattern. The novelty of this work lies in the development and experimental validation of a novel multilayered composite material with enhanced fracture resistance, which has not been explored previously for pressure vessel application. Mode I fracture toughness (<i>K</i><sub>IC</sub>) was experimentally determined (17.01&#xa0;MPa√m), which is significantly higher than the individual base polymer composites: M1 (3.25&#xa0;MPa√m), M2 (5.14&#xa0;MPa√m), and M3 (5.76&#xa0;MPa√m). To ensure reliability, a numerical analysis was conducted using extended finite element method (XFEM) in ABAQUS CAE, exhibiting a strong correlation with experimental results. The findings establish that the proposed IM overlay has the potential to improve fracture resistance.</p>

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Manufacturing and Fracture Toughness Evaluation on Innovative Material under Monotonic Load: Alternative Approach for Replacing Conventional Coating Material as an Overlay

  • 期刊论文

  • 发表日期：

    2025年5月16日

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  • Dhinakaran Veeman,
  • Balakumar Viswanathan,
  • Mohith Mohan Das,
  • Mohan Kumar Subramaniyan

摘要

Polymer coating and composite wrapping are extensively employed in pressure vessel structures due to their lightweight nature and superior corrosion resistance compared to full-metal vessels. However, conventional polymer coatings exhibit limited fracture toughness, leading to premature failure and increased maintenance costs. This study introduces an innovative material (IM) overlay, fabricated using a multilayered combination of wood-reinforced PLA (M1), carbon-reinforced PLA (M2), and ceramic-reinforced PLA (M3), arranged in a sequential M1–M2–M3 pattern. The novelty of this work lies in the development and experimental validation of a novel multilayered composite material with enhanced fracture resistance, which has not been explored previously for pressure vessel application. Mode I fracture toughness (KIC) was experimentally determined (17.01 MPa√m), which is significantly higher than the individual base polymer composites: M1 (3.25 MPa√m), M2 (5.14 MPa√m), and M3 (5.76 MPa√m). To ensure reliability, a numerical analysis was conducted using extended finite element method (XFEM) in ABAQUS CAE, exhibiting a strong correlation with experimental results. The findings establish that the proposed IM overlay has the potential to improve fracture resistance.