Multiscale fiber reinforced composites based on a carbon nanofiber/epoxy nanophased polymer matrix: Synthesis, mechanical, and thermomechanical behavior

Vacuum assisted resin infusion molding (VARIM) was used to produce multiscale fiber reinforced composites (M-FRCs) based on carbon nanofibers dispersed in an epoxy resin. Flexural, interlaminar shear strength (ILSS) and thermomechanical tests are presented for the 0.1 wt% and 1 wt% M-FRCs and compared with the neat fiber reinforced composites (FRCs). Flexural strength and modulus increased (16–20%) and (23–26%), respectively for the 0.1 wt% and 1 wt% M-FRCs when compared to the neat FRCs. ILSS properties increased (6% and 25%) for the 0.1 wt% and 1 wt% M-FRCs, respectively when compared to neat FRCs. The glass transition temperatures (T_g) of both M-FRC samples were 25 °C higher than the neat FRC. Coefficients of thermal expansion (CTE) of the M-FRC samples improved compared to the neat FRC. The improved T_g and CTE properties in the M-FRC samples are attributed to synergistic interactions between the CNF/PNC matrix and glass fibers.     

Macroscopic analysis of interfacial properties of flax/PLLA biocomposites

This study presents results from a study of the mechanical behaviour of flax reinforced Poly(l-Lactic Acid) (PLLA) under in-plane shear and mode I interlaminar fracture testing. Slow cooling of the unreinforced polymer has been shown to develop crystalline structure, causing improvement in matrix strength and modulus but a drop in toughness. The in-plane shear properties of the composite also drop for the slowest cooling rate, the best combination of in-plane shear performance and delamination resistance is noted for an intermediate cooling rate, (15.5 °C/min). The values of G_Ic obtained at this cooling rate are higher than those for equivalent glass/polyester composites. These macro-scale results have been correlated with microdroplet interface debonding and matrix characterization measurements from a previous study. The composite performance is dominated by the matrix rather than the interface.     

Synchronous effects of multiscale reinforced and toughened CFRP composites by MWNTs-EP/PSF hybrid nanofibers with preferred orientation

MWNTs-EP/PSF (polysulfone) hybrid nanofibers with preferred orientation were directly electrospun onto carbon fiber/epoxy prepregs and interlaminar synchronously reinforced and toughened CFRP composites were successfully fabricated. With MWNTs-EP loading increasing, the oriented nanofibers were obtained accompanying with enhanced alignment of inner MWNTs-EP. Flexural properties and interlaminar shear strength of composites were improved with increasing MWNTs-EP loadings, whereas fracture toughness attained maximum at 10 wt% MWNTs-EP loading and then decreased. Based on these results, multiscale schematic modeling and mechanism schematic of hybrid nanofibers reinforced and toughened composites were suggested. Due to the preferred orientation of nanofibers, MWNTs-EP was inclined to align vertically to carbon fiber direction along the in-plane of interface layer. The proposed network structures, containing four correlative phases of MWNTs-EP/PSF sphere/carbon fiber/epoxy matrix, contributed to simultaneous improvement of strength and toughness of composites, which was realized by crack pinning, crack deflection, crack bridging and effective load transfer.     

Torsion fatigue behavior of unidirectional carbon/epoxy and glass/epoxy composites

This paper presents results of the feasibility of carbon/epoxy composites (CFRP) as a future helicopter flexbeam material. Torsional behaviors of unidirectional CFRP and glass/epoxy composites (GFRP) with the same resin matrix were investigated. The initial torsional rigidity of CFRP was almost identical to that of GFRP. The torsional rigidities calculated using finite element analyses (FEA) agreed with the experimental results: the torsional rigidities are governed mainly by the material’s shear stiffness. Torsion fatigue tests were also conducted by controlling the angle of twist of the sinusoidal wave under a constant tensile axial load. No catastrophic failure occurred with either GFRP or CFRP, although decreased amplitudes of torque and torsional rigidities were observed according to the number of cycles. Results of X-ray CT inspections and numerical calculation by FEA revealed that degradation of a torsional rigidity is caused mainly by splitting crack propagation along the fiber direction. The torsion fatigue life of CFRP was superior to that of GFRP. Consequently, results confirmed that CFRP exhibits excellent properties as a torsional element of a helicopter flexbeam in terms of torsional rigidity and tension–torsion fatigue behaviors.     

Analysis of effect of fiber orientation on Young’s modulus for unidirectional fiber reinforced composites

Young’s modulus of unidirectional glass fiber reinforced polymer (GFRP) composites for wind energy applications were studied using analytical, numerical and experimental methods. In order to explore the effect of fiber orientation angle on the Young’s modulus of composites, from the basic theory of elastic mechanics, a procedure which can be applied to evaluate the elastic stiffness matrix of GFRP composite as an analytical function of fiber orientation angle (from 0° to 90°), was developed. At the same time, different finite element models with inclined glass fiber were developed via the ABAQUS Scripting Interface. Results indicate that Young’s modulus of the composites strongly depends on the fiber orientation angles. A U-shaped dependency of the Young’s modulus of composites on the inclined angle of fiber is found, which agree well with the experimental results. The shear modulus is found to have significant effect on the composites’ Young’s modulus, too. The effect of volume content of glass fiber on the Young’s modulus of composites was investigated. Results indicate the relation between them is nearly linear. The results of the investigation are expected to provide some design guideline for the microstructural optimization of the glass fiber reinforced composites.     

Expanded graphite nanoplatelets as coupling agents in glass fiber reinforced polypropylene composites

The interfacial adhesion between E-glass fibers and various types of nanomodified polypropylene (PP) matrices have been investigated on single-fiber model composites. In particular, an evaluation of the fiber–matrix interfacial shear strength was performed by the fragmentation tests on model composites prepared by using PP matrices containing various amounts (up to 7 wt%) of expanded graphite nanoplatelets (xGnP).The presence of xGnP in the polymer matrix resulted in a remarkable increase of the interfacial shear strength values (up to a factor of about 6 for a 7 wt% content of xGnP) if compared to neat PP. Moreover, wettability measurements in various liquids evidenced that the work of adhesion of the polymer matrix with respect to glass fiber, was improved by the presence of xGnP.     

Water absorption behavior,mechanical and thermal properties of nano TiO2 enhanced glass fiber reinforced polymer composites

Nano TiO₂ particle is one of the promising inorganic nano fillers used in polymer matrix composites to enhance the mechanical properties. However, reliability of this type of nano composites is yet to be ensured in hydrothermal environment. The present work investigates the addition of nano TiO₂ filler on water sorption, residual strength and thermal properties of glass fiber reinforced polymer (GFRP) composites. The results revealed that addition of 0.1 wt% TiO₂ has reduced water diffusion coefficient by 9%, improved residual flexural strength by 19% and residual interlaminar shear strength by 18% among all the nano TiO₂ modified composites. The improvement of mechanical properties in hydrothermal environment creates opportunity and reliability to be used in different engineering applications. Weibull design parameters are evaluated and found a good agreement between Weibull stress-strain curves and experimental one. Fractographic analysis confirmed the various failures and strengthening mechanisms of nano composites in dry and hydrothermal environment.     

Facile synthesis of lanthanum hypophosphite and its application in glass-fiber reinforced polyamide 6 as a novel flame retardant

This work developed flame retarded glass fiber reinforced polyamide 6 (FR-GFPA) composites with excellent mechanical properties, thermal stability and flame retardancy using a novel flame retardant, lanthanum hypophosphite (LaHP). The flame-retarded properties of FR-GFPA composites were characterized by limiting oxygen index, Underwriters Laboratories 94 testing and cone calorimeter test. FR-GFPA composite with 20 wt% LaHP reached V-0 rating and a high LOI value (27.5 vol%). The mechanical performance analysis showed that both the storage modulus and tensile strength increased and then decreased with the increase of LaHP loading. For FR-GFPA composite with 15 wt% LaHP loading, the storage modulus was 164% higher than that of glass fiber reinforced polyamide 6 (GFPA). Thermogravimetric analysis (TGA) and char residue characterization showed that the addition of LaHP can promote the formation of compact physical char barrier, reduce the mass loss rate and thus improve the flame retardancy of FR-GFPA composites.     

Processing a glass fiber reinforced vinyl ester composite with nanotube enhancement of interlaminar shear strength

Carbon nanotubes have been considered as a promising means of enhancing the properties of advanced composites in a range of polymer systems. Expected property enhancements include high strength and stiffness, improved toughness, impact and through-thickness properties. Z-axis properties like shear strength are of special interest for laminated composite structures subjected to transverse loads. This paper reports the processing of a glass fiber reinforced vinyl ester composite with nanotube integration and examines the reinforcement potential on interlaminar shear strength. Several sidewall functionalized nanotube derivatives were also prepared in order to obtain high dispersion and matrix bonding. Carbon nanotube enhanced vinyl ester/glass fiber composites were fabricated by a vacuum assisted resin transfer molding process. Overcoating the glass fiber weave with nanotubes and processing modification led to enhancement of the interface properties. A maximum of 45% increase in shear strength over control sample was observed on several types of nanotubes with a very small amount of nanotubes (0.015 wt%) coated in the midplane ply.     

Investigation on adhesion, interphases, and failure behaviour of cyclic butylene terephthalate (CBT)/glass fiber composites

Interphases exist in hybrid materials and significantly influence their mechanical performance. To find a bridge between the microscopic and macroscopic mechanical properties, this work investigates the microscopic nature of glass fiber surfaces and glass/CBT interphases in terms of topography, fractography, and adhesion properties. The variations in glass fiber surface properties result from the different sizings. Using the single fiber pull-out test, AFM, and ζ potential tests, it is shown that the interfacial bond strengths in CBT resin composites can vary depending on the kind of sizing formulation and properties. The greatest adhesion strength is achieved by aminosilane sizings with epoxy resin film former. The surface roughness of the fibers can be varied by sizings with different content and ζ potential values, which has no significant contribution to interphase adhesion strength from ‘mechanical interlocking’. For the systems with film formers, cohesive failure occurs and similar values of both interfacial adhesion strength, τ_d, and fracture energy release rate, G_ic, are obtained, in which τ_d approaches the shear yield strength of CBT matrix. A further enhancement of interfacial adhesion is limited by the mechanical properties and the non-homogeneous microstructure of CBT resin due to the less-than-perfect CBT polymerization.     

Structurally stitched NCF CFRP laminates. Part 1: Experimental characterization of in-plane and out-of-plane properties

The insertion of local through-thickness reinforcements into dry fiber preforms by stitching provides a possibility to improve the mechanical performance of polymer-matrix composites perpendicular to the laminate plane (out-of-plane). Three-dimensional stress states can be sustained by stitching yarns, leading to increased out-of-plane properties, such as impact resistance and damage tolerance. On the other hand, 3D reinforcements induce dislocations of the in-plane fibers causing fiber waviness and the formation of resin pockets in the stitch vicinity after resin infusion which may reduce the in-plane stiffness and strength properties of the laminate.In the present paper an experimental study on the influence of varying stitching parameters on in-plane and out-of-plane properties of non-crimp fabric (NCF) carbon fiber/epoxy laminates is presented, namely, shear modulus and strength as well as compression after impact (CAI) strength and mode I energy release rate. The direction of stitching, thread diameter, spacing and pitch length as well as the direction of loading (which is to be interpreted as the direction of the three rail shear loading or the direction of crack propagation in case of mode 1 energy release rate testing) were varied, and their effect on the mechanical properties was evaluated statistically.The stitching parameters were found to have ambivalent effect on the mechanical properties. Larger thread diameters and increased stitch densities result in enhanced CAI strengths and energy release rates but deteriorate the in-plane properties of the laminate. On the other hand, a good compromise between both effects can be found with a proper selection of the stitching configurations.     

碳/碳复合材料疲劳损伤失效试验研究

对单向碳/碳复合材料纵向拉-拉疲劳特性及面内剪切拉-拉疲劳特性进行了试验研究; 对三维四向编织碳/碳复合材料的纵向拉-拉疲劳特性及纤维束-基体界面剩余强度进行了试验研究。使用最小二乘法拟合得到了单向碳/碳复合材料纵向及面内剪切拉-拉疲劳加载下的剩余刚度退化模型及剩余强度退化模型, 建立了纤维束-基体界面剩余强度模型。结果显示: 单向碳/碳复合材料在87.5%应力水平的疲劳载荷下刚度退化最大只有8.8%左右, 在70.0%应力水平的疲劳载荷下, 面内剪切刚度退化最大可达30%左右; 三维四向编织碳/碳复合材料疲劳加载后强度及刚度均得到了提高; 随着疲劳循环加载数的增加, 三维四向编织碳/碳复合材料中纤维束-基体界面强度逐渐减弱。      

Glass fiber reinforced high glass transition temperature thiol–ene networks

Although thiol–ene polymers have highly desirable processing properties the networks usually are limited to having characteristically low glass transition temperatures with low strength. This study is one of the first studies to examine a thiol–ene polymer thermoset matrix, having many industrial advantages compared to conventional polymer matrices, reinforced with continuous E-glass fibers. In order to control the interphase, a mercapto functional sizing of 1 wt% is applied to the glass fibers. The resulting composites of 12 vol% fibers are comparable to glass fiber reinforced polyesters in terms of strength with Young’s modulus. This work contributes to the furthering of thiol–ene ultra-violet cure systems, with their range of advantageous properties, for use in a broader scope of applications by way of creating a stronger material based on a novel class of thermoset matrix.     

The effect of interfacial state on the thermal conductivity of functionalized Al2O3 filled glass fibers reinforced polymer composites

Rapidly increasing packaging density of electronic devices puts forward higher requirements for thermal conductivity of glass fibers reinforced polymer (GFRP) composites, which are commonly used as substrates in printed circuit board. Interface between fillers and polymer matrix has long been playing an important role in affecting thermal conductivity. In this paper, the effect of interfacial state on the thermal conductivity of functionalized Al₂O₃ filled GFRP composites was evaluated. The results indicated that amino groups-Al₂O₃ was demonstrated to be effective filler to fabricate thermally conductive GFPR composite (1.07 W/m K), compared with epoxy group and graphene oxide functionalized Al₂O₃. It was determined that the strong adhesion at the interface and homogeneous dispersion of filler particles were the key factors. Moreover, the effect of interfacial state on dielectric and thermomechanical properties of GFRP composites was also discussed. This research provides an efficient way to develop high-performance GFRP composites with high thermal conductivity for integrated circuit packaging applications.     

Influence of hygrothermal aging on carbon nanofiber enhanced polyester material systems

Four polyester composites (neat polyester, polyester reinforced with glass fibers, polyester reinforced with carbon nanofibers, and polyester reinforced with both glass fibers and carbon nanofibers) were prepared with the Vacuum Assisted Resin Transfer Molding (VARTM) process. These material systems were exposed to 60 °C/60% RH for 3600 h. Diffusivity was determined using moisture uptake curves. And, it was discovered that the addition of glass fibers (GFs) increased diffusivity, while the addition of carbon nanofibers (CNF) decreased diffusivity. Optical analysis was performed on the manually delaminated glass fiber reinforced polymer (GFRP) and nano-enhanced GFRP. This analysis indicated that the addition of CNF retarded the degradation of the matrix after exposure to elevated heat and humidity. Thermo-mechanical analysis was performed across material systems during various stages of the environmental preconditioning to determine alterations in properties such as storage modulus (SM) and glass transition temperature (T_g). The addition of GF to the system initially increased the maximum storage modulus, it also increased degradation from elevated heat and humidity exposure In contrast with GF, the addition of CNF retarded SM degradation and increased thermal stability. Upon re-drying, the nano-enhanced material systems recouped more than 90% of the maximum SM and maintained a T_g between the baseline and saturated hygrothermal treatments. This indicated both a reversible plasticization and an irreversible retarded degradation which could be potentially attributed to the addition of CNF.     

Linear and nonlinear torsional behavior of unidirectional CFRP and GFRP

The helicopter bearingless rotor flexbeam is usually made of glass-fiber reinforced plastic composite (GFRP). Carbon-fiber composites (CFRP) are candidate for future flexbeam materials due to their superior tensile fatigue strength. This research examines the feasibility of CFRP as a future flexbeam material. The torsion behaviors of unidirectional CFRP and GFRP with the same matrix resin were investigated. As a result, it was confirmed that the behavior of both CFRP and GFRP is comprised of linear/nonlinear domains. The initial torsional rigidity of CFRP was almost the same as that of GFRP. The torsional rigidities calculated from Lekhnitskii’s equations agreed with the experimental results, and they are mainly determined by the shear stiffness of the materials. The nonlinear torsional behavior was observed above 0.5% of the shear strain, and it is due to plastic deformation of the matrix resin. A 3D plasticity model proposed by Sun et al. was applied to the plasticity parameters obtained from off-axis tensile tests. The numerical curves agree with the experimental data below 1.5% of the shear strain. The experimental result suggests that GFRP can be replaced by CFRP as torsional elements of a helicopter flex beam without an increase in torsional rigidity.     

Processing dependent morphology, interfacial interaction and shear behavior of short carbon fiber reinforced PEEK

Shear properties of compression-molded discontinuous AS4 carbon fiber reinforced poly(ether ether ketone) composites are evaluated with Iosipescu tests. It is found that both shear modulus and shear strength strongly depend on the molding conditions. A comparison between shear behavior of the composites and composites morphology reveals that fusion of the composite pellets and fiber/matrix interfacial interaction on molecular scale are the two dominant factors which determine the processing dependent shear properties of the materials studied.     

Hybrid multi-scale epoxy composite made of conventional carbon fiber fabrics with interlaminar regions containing electrospun carbon nanofiber mats

Herein we report the development and evaluation of hybrid multi-scale epoxy composite made of conventional carbon fiber fabrics with interlaminar regions containing mats of electrospun carbon nanofibers (ECNs). The results indicated that (1) the interlaminar shear strength and flexural properties of hybrid multi-scale composite were substantially higher than those of control/comparison composite without ECNs; in particular, the interlaminar shear strength was higher by ∼86%; and (2) the electrical conductivities in both in-plane and out-of-plane directions were enhanced through incorporation of ECNs, while the enhancement of out-of-plane conductivity (∼150%) was much larger than that of in-plane conductivity (∼20%). To validate the data reduction procedure, a new shear stress formula was formulated for composite laminates, which took into account the effect of layup and inter-layers. The study suggested that ECNs could be utilized for the development of high-performance composites, particularly with the improved out-of-plan properties (e.g., interlaminar shear strength).     

Mechanical and thermal behavior of non-crimp glass fiber reinforced layered clay/epoxy nanocomposites

Mechanical and thermal properties of non-crimp glass fiber reinforced clay/epoxy nanocomposites were investigated. Clay/epoxy nanocomposite systems were prepared to use as the matrix material for composite laminates. X-ray diffraction results obtained from natural and modified clays indicated that intergallery spacing of the layered clay increases with surface treatment. Tensile tests indicated that clay loading has minor effect on the tensile properties. Flexural properties of laminates were improved by clay addition due to the improved interface between glass fibers and epoxy. Differential scanning calorimetry (DSC) results showed that the modified clay particles affected the glass transition temperatures (T_g) of the nanocomposites. Incorporation of surface treated clay particles increased the dynamic mechanical properties of nanocomposite laminates. It was found that the flame resistance of composites was improved significantly by clay addition into the epoxy matrix.     

Mechanical characterization of hierarchical carbon fiber/nanofiber composite laminates

Susceptibility to matrix driven failure is one of the major weaknesses of continuous-fiber composites. In this study, helical-ribbon carbon nanofibers (CNF) were dispersed in the matrix phase of a continuous carbon fiber-reinforced composite. Along with an unreinforced control, the resulting hierarchical composites were tested to failure in several modes of quasi-static testing designed to assess matrix-dominated mechanical properties and fracture characteristics. Results indicated CNF addition offered simultaneous increases in tensile stiffness, strength and toughness while also enhancing both compressive and flexural strengths. Short-beam strength testing resulted in no apparent improvement while the fracture energy required for the onset of mode I interlaminar delamination was enhanced by 35%. Extrinsic toughening mechanisms, e.g., intralaminar fiber bridging and trans-ply cracking, significantly affected steady-state crack propagation values. Scanning electron microscopy of delaminated fracture surfaces revealed improved primary fiber–matrix adhesion and indications of CNF-induced matrix toughening.