3D Braided Composites Research Articles

Comprehensive analysis of the effect of braiding angle on the wettability and mechanical properties of 3D braided carbon fiber fabric-reinforced composites

Fiber-reinforced composites are designed to enhance strength, stiffness, and lightweight properties. However, while the use of continuous fibers offer substantial performance benefits it presents challenges in achieving complex configurations. This study focused on evaluating the effects of different braiding angles on the mechanical properties of braided fabric-reinforced composites (B-CFRP). Continuous fiber tows were braided around a mandrel, with meticulous control over the key process parameters to ensure consistency. The composites were then processed using the Vacuum Assisted Resin Transfer Molding (VARTM) technique to achieve optimal impregnation of the resin. Mechanical properties, including tensile, flexural, compressive strength, interlaminar shear strength (ILSS), and impact strength, were performed to establish the relationship between resin impregnation and mechanical properties with different braid angles. Additionally, resin flow experiments and scanning electron microscopy (SEM) analysis were conducted to investigate how variations in braiding angle influence fiber arrangement, resin distribution, and fracture behavior. These insights aim to guide the design and manufacturing of high-performance composites.

Investigation of the dynamic compression behavior of 3D braided composites based on a virtual fiber embedding method

The three-dimensional braided composites (3DBCs) possess a complex spatial structure, which can lead to microscopic deformation of fibers under high-speed impact. This paper proposes a quasi-fiber scale model using virtual fiber-embedded (VFE) method to simulate the impact behavior and failure of 3DBCs. The results reveal that the maximum eccentricity of the VFE model yarn cross-section is 0.318, representing a 194% improvement compared to solid yarns. According to the characteristics of damage, it can be deduced that interactions among fibers play a pivotal role in determining the failure behavior of composites, particularly concerning non-linear changes. The modulus, strength and the time of initial damage rise with an increasing braiding angle, whereas the resin stress, yarn stress, and degree of damage exhibit opposite trends. The stress distribution over the braiding path shows that the main load-bearing component at 20° braiding angles is internal yarns, whereas the surface yarns take precedence at 40°. The maximum deformation of the yarn cross-section always occurs at the center of the shear band, with a maximum eccentricity of 0.456 at 20° braiding angles. The deformation in yarn flexing and cross-section flattening cause an uneven distribution of stress and strain, leading to localized damage and ultimately catastrophic destruction.

Investigation of the static and low‐velocity impact performance of 3D braided spacer composites

AbstractTo meet the lightweight requirements of advanced composite materials, the ultralightweight three‐dimensional (3D) braided spacer composites were designed and manufactured by ultra‐high molecular weight polyethylene (UHMWPE). The key structural effects of core column distances and core column heights on the static bending, compression, and low‐velocity impact properties of the composites were further investigated. Results indicated that the mechanical properties of 3D braided spacer composites was closely depended on their structural parameters. The flexure and compression of 3D braided spacer composites decreased with increasing core column distance and core column height. W1/H1 specimen showed the optimal bending and compressive performance. The maximum flexural strength and flexural modulus were approximately 54.77 MPa and 4.95 GPa, respectively. The low‐velocity impact properties were further investigated where the stiffness, energy absorption, and impact resistance of the composite decreased with increasing core column distance. The peak load and energy absorption of the W1 specimen were 2.39 kN and 7.99 J, respectively. While the low‐velocity impact properties increased with increasing core column distance. The H3 specimen exhibited the greatest stiffness, impact resistance and energy absorption with peak loads and energy absorption of 2.81 kN and 8.49 J, respectively. In addition, the macro morphology and scanning electron microscopy (SEM)micrographs were examined to investigate the damage morphology and failure mechanism of the composites. The main failure modes were matrix cracking, interface debonding, fiber buckling, and dislocation, as well as tilting, and failure of the core columns. This work provides guidance for structural design and engineering application of 3D lightweight braided spacer composite.

Multifunctional 3D carbon fiber/epoxy braided composites with excellent compression performance and electromagnetic interference shielding

The multifunctional composites with electromagnetic interference (EMI) shielding performance and mechanical property are in urgent demand. In this work, the carbon fibers reinforced 3D braided preforms (3DBPs) were fabricated by a four-step braiding method. Then, the 3D braided composites (3DBCs) were prepared via vacuum assisted resin transfer molding technique. The establishment of a comprehensive 3D conductive network conferred upon the 3DBCs an exemplary EMI shielding efficiency of 54.01 dB in the X-band. Furthermore, the 3DBPs served the reinforcing function, attaining an exceptional compressive strength of 211.48 MPa at a density of 1.37 g/cm3. It is of great significance to apply the 3D braiding technology to develop EMI shielding composites to realize the structure-function integration.

Towards accurate prediction of the dynamic behavior and failure mechanisms of three-dimensional braided composites: A multiscale analysis scheme

In this paper, a dynamic multiscale model is proposed for three-dimensional four-directional (3D4D) braided composites, considering the effects of strain rate and shear enhanced failure mechanism. The strain rate-dependent constitutive models are established for both resin and yarns. The accuracy of the yarn model is validated by comparing the simulated stress-strain curves with the experimental results obtained from the Split Hopkinson Pressure Bar (SHPB) tests with various strain rates. The shear enhancement coefficient of the yarn is determined from the failure envelopes with a discussion of crack propagation angles. The results show that, based on the calculated microscale properties, the mesoscale model accurately predicts both the longitudinal and transverse compressive strain-stress behavior of 3D4D braided composites at different strain rates. A comparative analysis reveals that the shear-enhanced failure model achieves a better prediction compared with other counterparts, such as Hashin-Rotem and Tsai-Wu Models. The proposed dynamic multiscale scheme for 3D braided composites is an efficient and accurate tool to characterize their multiscale features and strain rate-dependent behavior.

Fatigue damage evolution and residual strength analysis of 3D5D braided composites using X-ray computed tomography, acoustic emission, and digital image correlation

The accumulation of fatigue damage leads to continuous degradation of the residual strength of three-dimensional braided composites, directly determining the fatigue life. However, the inability to continuously collect residual strength and multiple damage modes pose a challenge to study the residual strength degradation mechanisms of three-dimensional braided composites. In this work, digital image correlation and acoustic emission techniques are employed to assess the strain field and damage events of the specimens during the residual strength tests. X-ray computed tomography facilitates the visualization and quantification of the fatigue damage evolution in three-dimensional braided composites. Moreover, the “two-step” damage classification method is applied to isolate the damage mechanisms. The Pearson correlation analysis is preformed between the quantitative results of three non-destructive techniques and residual strength degradation of 3D braided composites. The integration of the outcomes provides a comprehensive depiction of the residual strength degradation mechanisms.

Deep learning and integrated approach to reconstruct meshes from tomograms of 3D braided composites

The meticulous reconstruction of three-dimensional (3D) braided composite materials serves as a crucial foundation for achieving high-fidelity simulations. Nonetheless, the transition from tomographic images to a 3D mesh entails a laborious and time-intensive process. To address this, an integrated procedure based on artificial intelligence is proposed for reconstructing meshes from tomograms. The initial stage of the process involves employing artificial intelligence techniques to segment complex contours and optimize high-dimensional contours. This facilitates the input of high-quality images needed to reconstruct accurate digital twins with strong convergence. The subsequent reconstruction phase integrates various calculations, including shape interpolation, contour extraction, 3D surface reconstruction, 3D mesh reconstruction, and element data interpolation. During this process, optimization objectives are set to minimize the deviation between the digital twin's surface and the actual surface, as well as to optimize the aspect ratio of the element mesh. Upon completion of the aforementioned steps, high-quality input files suitable for finite element calculations are directly generated. Ultimately, the proposed method utilizes the reconstructed finite element model for mechanical analysis, and the results are found to be in good agreement with experimental tests. This method offers an efficient and rapid way to achieve high-quality reconstruction of complex digital twins.

Electro-Mechanical Coupling Analysis of L-Shaped Three-Dimensional Braided Piezoelectric Composites Vibration Energy Harvester.

In this article, an L-shaped three-dimensional (3D) braided piezoelectric composite energy harvester (BPCEH) is established, which consists of an elastic layer composed of a 3D braided composite, flanked by upper and lower layers of piezoelectric material and two tuning mass blocks. Glass fiber and epoxy resin are used to produce a 3D braided composite. This L-shaped 3D BPCEH is mechanically designable and can be adapted to different work requirements by varying the braided angle of the 3D braided composite layer. The material parameters of 3D braided composites are predicted for different braided angles by means of a representative volume element (RVE). Electro-mechanical coupled vibration equations for the L-shaped 3D BPCEH are established. The impact of braided angles on voltage and power output is discussed in this article. Simulations using finite element method are conducted to analyze the voltage and power output responses at various braided angles. In addition, the effects of the mass of mass block B and the length of the beam on the output performance of the L-shaped 3D BPCEH are analyzed.

Research on foldable two-matrix 3D braided composites: Manufacturing and bending progressive damage

Research on foldable two-matrix 3D braided composites: Manufacturing and bending progressive damage

FCA-based efficient prediction of effective properties for 3D braided composites considering the effect of strain rate

The existing fast concurrency algorithms are difficult to predict the dynamic mechanical performance of three-dimensional (3D) braided composites from different scales. A modified Finite Element Method Cluster Analysis (FCA) method is employed to address this challenge. The modified FCA method is consisted of an offline and an online stage. In the offline stage, the high-fidelity Representative Unit Cell (RUC) is compressed to form a cluster-based RUC via the k-means method. Additionally, the cluster interaction matrix is calculated. In the online stage, the cluster interaction matrix is updated according to the strain rate levels for predicting the stress–strain curves for the RUC. Based upon the comparison with the data obtained from the Split Hopkinson Pressure Bar (SHPB) experiments, it is found that the modified FCA method can accurately predict the stress–strain curves under different strain rates for RUCs. Additionally, the modified FCA method provides a great improvement on computing efficiency when predicting the dynamic behavior of 3D braided composites.

Irradiation multi-scale damage and interface effects of 3D braided carbon fiber/epoxy composites subjected to high dose γ-rays

The serious damage caused to 3D braided carbon fiber (CF)/epoxy (EP) composites in high-energy irradiation environments is a pressing research topic that has not yet been reported. This study analyzed the γ-irradiation multi-scale damage of the matrix, interfaces, and near-interface regions in 3D braided CF/EP composites with three different braiding angles (18°, 28°, 38°) at atomic, microscopic, and macroscopic scales. The molecular structure and atomic charge information alterations of epoxy matrix were characterized using soft X-ray absorption spectroscopy (sXAS). When the irradiation dose reached 1000 KGy, the compressive strength of composites decreased by 20.88 %, 18.07 %, and 16.60 %, respectively, with an increase in the braiding angle. Micro-CT observation, along with statistical computing, confirmed that irradiation causes interface damage and increases the defect volume of 3D braided composites. Nanoindentation was used to compare the modulus of carbon fiber, interface, near-interface regions and matrix in irradiated composites and the function of CF/resin interface as an irradiation defect capture site in the irradiation resistance of resin-matrix composites has been newly established. In addition, the mechanism behind the effect of braiding angle on macroscopic properties was also analyzed.

A novel modeling method to study compressive behaviors of 3D braided composites considering effects of fiber breakage and waviness defects

Fiber breakage and waviness defects are two significant and inevitable defects existing in three-dimensional braided composites (3DBCs). This work proposed a new method to create the numerical model containing fiber breakage and waviness defects at the micro-scale level according to experimental characterization results. The experimental tests of 3DBCs with various braiding angles and matrix types are then designed to verify the reliability and adaptability of the model. The results indicate that the fiber breakage and waviness defects both gave rise to an apparent decrease in the axial mechanical properties of the unidirectional and braided composites. The influences of two kinds of defects on 3DBCs are also related to the braiding angles. In addition, the effect of matrix type on the 3DBC is apparent that should not be neglected. The primary reasons of the change of compressive properties of 3DBCs with different matrix types are the variations of the matrix and interfacial properties. The proposed modeling method in this work can be extended for those composites that include a large quantity of fiber breakage and waviness defects.

Theoretical Analysis of Thermophysical Properties of 3D Carbon/Epoxy Braided Composites with Varying Temperature.

A three-dimensional helix geometry unit cell is established to simulate the complex spatial configuration of 3D braided composites. Initially, different types of yarn factors, such as yarn path, cross-sectional shape, properties, and braid direction, are explained. Then, the multiphase finite element method is used to develop a new theoretical calculation procedure based on the unit cell for predicting the impacts of environmental temperature on the thermophysical properties of 3D four-direction carbon/epoxy braided composites. The changing rule and distribution characteristics of the thermophysical properties for 3D four-direction carbon/epoxy braided composites are obtained at temperatures ranging from room temperature to 200 °C. The influences of environmental temperature on the coefficients of thermal expansion (CTE) and the coefficients of thermal conduction (CTC) are evaluated, by which some important conclusions are drawn. A comparison is conducted between theoretical and experimental results, revealing that variations in temperature exert a notable influence on the thermophysical characteristics of 3D four-directional carbon/epoxy braided composites. The theoretical calculation procedure is an effective tool for the mechanical property analysis of composite materials with complex geometries.

Defect effect on high strain rate compressive behaviors of 3D braided composites

Defect effect on high strain rate compressive behaviors of 3D braided composites

A new progressive fatigue damage model for the three-dimensional braided composites subjected to locally-variable-amplitude loading

The fatigue-induced stress redistribution in three-dimensional (3D) braided composites, even when subjected to externally constant-amplitude fatigue loads, results in locally-variable-amplitude fatigue loading, significantly impacting their fatigue performance degradation. This paper is aimed to propose a novel fatigue damage analysis method to predict the fatigue behavior of 3D braided composites subjected to locally-variable-amplitude loading. To this end, the continuous damage method, residual strength, residual stiffness, and fatigue life models are combined to characterize the properties degradation of 3D braided composites with cycling. Once stress redistribution occurs, the fatigue properties degrade based on the new stress level, and the equivalent cycle number is recalculated accordingly. As the material undergoes different cycle blocks, damage accumulates, ultimately leading to failure when the overall stiffness of the material degrades to 80%. Traditional fatigue models are also employed to predict the fatigue behavior of representative volume elements for comparison. The results predicted by the present model shows good agreement with experiments. Furthermore, the influence of stress levels and architectures of 3D braided composites on fatigue performance is systematically discussed.

Shape memory behaviors of three-dimensional five-directional braided composites with different axial yarns arrangements

The effect of braided structure on shape memory behaviors of 3D braided composites is critical to design the responses of the composite under external fields. Here we report the effect of axial yarn on shape memory behaviors of three-dimensional five-directional (3D5d) braided shape memory polymer composites (SMPCs) under bending. It was found that the axial yarns will improve bending stiffness and electro-thermal behaviors significantly. The thermomechanical deformation and shape memory effect of SMPCs are influenced by the braiding structural parameters. Specifically, the 3D5d SMPCs exhibits a 53.6% increase in bending recovery force and a faster shape recovery speed than those of 3D four-directional SMPCs. We found from finite element analyses (FEA) that the axial yarns positions influence the inner stress distribution and shape memory behaviors of SMPCs. The axial yarns distributed on both sides of SMPC influence the shape memory behaviors more than those of the middle layer.

Trans-scale analysis of 3D braided composites with voids based on micro-CT imaging and unsupervised machine learning

Voids are unavoidable during the manufacturing of 3D braided composites. This study proposes an unsupervised machine learning method combined with micro-computed tomography (micro-CT) scanning and a progressive damage analysis to analyze defects in these composites at a trans-scale level. The method enables the creation of real multiscale models and the determination of the porosity in both the intra-yarn (1.52 %) and inter-yarn (5.04 %) planes. Here, the unsupervised machine learning method is introduced in a trans-scale damage analysis to reduce calculation dimensions and to visualize the clustering data. A user-defined material subroutine (UMAT) is also developed to implement the trans-scale damage model. The experimental validation of the simulation results demonstrates the effective trans-scale damage analysis, showing the predominant pull-shear damage in the yarns, which is primarily located at the interfaces both between the yarns and between the yarns and the matrix. Finally, based on the scanned geometric data the degradation in modulus and strength of 3D braided composites with porosity is studied.

Tensile damage self-monitoring of carbon fiber/epoxy 3D braided composites with electrical resistance method

Electrical resistance method (ERM) has great potential in self-monitoring structural health for carbon fiber composites due to carbon fiber conductivity. Here we report the correlation between tensile damages and electrical resistance changes of 3D braided composites subjected to monotonic and cyclic tensile loading. Experimental and finite element methods were utilized to reveal the electrical resistance variation and damage evolution under monotonic tensile loading. We found that the electrical resistance changes under monotonic tensile loading could be segmented into three regions, namely, linear growth region, transition region and exponential growth region, corresponding to different damage modes. Synchronous and reversible electrical resistance changes at a low strain level (12% of fracture strain) cyclic loading proved the stability and repeatability of self-monitoring capability. While, the abrupt electrical resistance changes at a high strain level (75% of fracture strain), indicated catastrophic failure of the composites. Such kind of correspondence between tensile damages and electrical resistance change under tensile loading enables ERM to achieve the in-situ structural health monitoring of 3D braided composites without relying on external sensors.

Prediction of elastic properties of 3D4D rotary braided composites with voids using multi-scale finite element and surrogate models

The conventional evaluation of 3D braided composites' mechanical properties through numerical and experimental methodologies serves as a hindrance to material application owing to the considerable expenses, time constraints, and laborious efforts involved. Moreover, the presence of void defects induced during the processing exacerbates this challenge. In this study, a multi-scale finite element model (FEM) and a surrogate model are established for predicting elastic properties of three dimensional four directional (3D4D) rotary braided composites with voids for the first time. Based on the established FEM, a comprehensive dataset containing 768 data points is formed, covering the ranges of both design parameters and void defect parameters. The influence of braiding angle, yarn width, and porosity, on the elastic constants of 3D4D rotary braided composites is accurately analyzed. A genetic algorithm-optimized back propagation neural network (GABPNN) model is developed, which possess the capability to replicate FEM outcomes with a commendable R-value of 0.99. The remarkable concordance between the anticipated outcomes and experimental datasets corroborates the triumphant implementation of the present method in unraveling the interconnections between microstructure and properties in 3D4D rotary braided composites containing voids. Consequently, this offers a propitious instrument for expediting the intelligent conception and refinement of composite materials.

An effective multiscale analysis for the mechanical properties of 3D braided composites considering pore defects

An effective multiscale analysis for the mechanical properties of 3D braided composites considering pore defects