Flexural and fracture behavior of additively manufactured carbon fiber reinforced polymer composites with bioinspired Bouligand meso-structures

Abstract

Carbon fiber reinforced polymer (CFRP) composites are strong and lightweight materials extensively used across aerospace, automotive, and construction industries. Bioinspired designs such as Bouligand structures have the potential to improve the mechanical properties of CFRP composites. In this study, we examine the effects of the single and double Bouligand meso-structures with varying twist angles on the flexural and fracture properties of additively manufactured continuous CFRP composites. 3-point flexural tests are conducted to characterize the flexural properties such as flexural modulus, strength, and energy absorption. Single edge notch bend (SENB) tests are performed to quantitively characterize the mode I fracture toughness and effective fracture energy. The elasto-plastic fracture theory is used to quantify the contributions of elastic and plastic energies to the effective fracture energy. Experimental results indicate that twist angles significantly affect the flexural behavior of CFRP composites. The Bouligand meso-structures with a twist angle of 10° increase the flexural strain energy absorption by 2-3 times. The single and double Bouligand layup configurations with the same twist angle result in different flexural properties. In addition, the twist angle affects the magnitude of fracture toughness. A twist angle of 10° results in an improvement of up to 60% in fracture energy dissipation compared to the quasi-isotropic meso-structure. The single and double Bouligand meso-structures with the same twist angle exhibit almost the same fracture toughness and absorbed fracture energy. The Bouligand meso-structures do not increase fracture toughness and elastic fracture energy for crack initiation compared to the quasi-isotropic meso-structure.