Mechanisms of damage and fracture of aramid fibers: Focus on the role of microfibril cooperativity in fracture toughness

Pushing the limits of synthetic polymers in terms of stiffness and strength, aromatic polyamide fibers–like Kevlar®–are used for demanding applications in the form of fiber assemblies as ropes. The unique mechanical performance of aramid fiber is intimately linked to its hierarchical structure and orientation, induced during the spinning process. Surprisingly, after nearly 60 years of heavy use, very little is known about damage mechanisms and rational explanation of such high resistance. We report an experimental investigation of the fiber damage mechanisms at the single fiber scale (diameter ≅ 10 μm) with the aim to establish a link with the microstructure. Damage mechanisms and crack propagation are observed in situ for the first time and unveil a widespread damage over the entire length of the fiber in the form of a network of transverse and longitudinal cracks. These observations make it possible to draw a novel scenario of fracture that mitigates the small strain failure hypothesis. To shed light on the crucial role of microfibril cooperativity in fracture toughness, a slight twist is applied to the single fiber to promote tortuosity and frictional contacts between microfibrils. Statistical fracture analysis demonstrated the beneficial impact of such torsion on early failure events, since lowest fracture stresses are shifted to higher stresses.