A detailed study of conditions leading to fiber fracture during the co
nsolidation of Ti-14wt%Al-21wt%Nb/SiC (SCS-6) composite monotapes has
been conducted. For this continuous fiber reinforced composite system,
the incidence of fracture increases with consolidation rate at higher
process temperatures. Increasing consolidation temperature at a fixed
pressure reduces the number of breaks per unit length of fiber. Exami
nation of partially densified compacts has revealed the existence of s
ignificant fiber bending and ultimately fracture due to monotape surfa
ce roughness (asperities) which places the fibers in three point bendi
ng. A representative volume element has been defined for the consolida
ting lay-up and its response analyzed to predict the fiber deflection
(and hence probability of failure) when the surface asperities deform
either by plasticity or by steady state creep. The relationships betwe
en fiber fracture and process conditions predicted using the volume el
ement are similar to those observed experimentally. The cell analysis
suggests that fiber fracture is decreased by increases in fiber stiffn
ess, strength, and diameter and by decreases in matrix yield and creep
strength and monotape surface roughness.