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Figure 18 shows the stages of the impact test. Upon impact, one can see elastic deformation (indentation and elastic bending), which is followed by the formation of cracks and ultimately complete penetration. As seen in the last frame for the foamed sample (t = 10.5 ms), the crack propagates in the same direction as the flow path during mold filling. Since fibers are predominantly aligned with the flow, the sample is more resistant to failure due to bending in this direction [42]. Figure 19 illustrates the anisotropic microstructure and how fibers in plane B-B are normal to the load direction in the outer regions where stresses are highest. In this plane (B-B), the matrix will carry most of the load near the part surface leading to an earlier failure, most likely due to debonding. This mode of failure is known as transverse cracking [66,67].
Crack propagation was evaluated using micro-CT scans. Figure 20 shows examples of the secondary cracks formed perpendicular to the main crack direction. The presence of the foam core can have different effects on the crack propagation behavior due to hindrance caused by air cells. This can force the crack to undergo a tortuous path, which reduces the extent of crack propagation. In some cases, the crack can deviate from a straight path by following a weaker path generated by large cells and changes in fiber density [68]. For example, Figure 20 (left) shows the upper crack avoiding a high FC region caused by undispersed fiber bundles. In other cases, cells can relieve the high stresses at the tip of the crack and stop crack propagation [69,70].
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