Temperature effect on the static and fatigue performance of thermoset and thermoplastic composites

The growing demand for lightweight, durable, and high-performance materials in industries such as aerospace, automotive, and energy has driven the development and evaluation of thermoset and thermoplastic composites. This study investigates the static and fatigue behavior of one thermoset material and two thermoplastic composites at varying temperatures (-30°C, 22°C, and 120°C) to simulate extreme environmental conditions. Experimental tests were conducted to evaluate mechanical performance and fatigue strength, focusing on the influence of temperature on strength and life cycles. The results highlight the significant impact of temperature on static properties and fatigue behavior, offering critical insights into their application in temperature-sensitive environments. A numerical modeling approach was applied to predict fatigue behavior by incorporating the effects of mean stress and temperature. Different fatigue damage models, including temperature-dependent formulations, were implemented to evaluate their predictive capabilities. The study compares traditional and advanced models, emphasizing their accuracy in replicating experimental results under combined mechanical and thermal loading. This research is partially funded by the Italian Ministry of Enterprises and Made in Italy (MIMIT) within the broader project "New Generation of Modular Intelligent Oleo-dynamic Pumps with Axial Flux Electric Motors," submitted under the "Accordi per l'Innovazione" call (DM 31/12/2021, DD 10/10/2022, automotive sector). The integrated experimental-numerical approach provides a comprehensive understanding of the mechanical response of thermoset and thermoplastic materials, contributing to the optimization of material selection and design processes for applications in harsh environments.