Anisotropic Carbon Fiber Research Articles

Local wavenumber imaging in anisotropic structures

Local wavenumber imaging has been proven effective for damage detection in thin-walled structures. Such structures are, however, often inherently anisotropic, posing serious challenges to the known algorithms of local wavenumber mapping. The use of local wavenumber mapping algorithm designed for isotropic, rather than anisotropic, structures results in processing artifacts that may prohibit correct detection and characterization of defects. Therefore, in this work, we propose an improved implementation of the local wavenumber estimation algorithm for anisotropic media (ALWE). The working principle and efficiency of the proposed algorithm are illustrated on datasets coming from numerical simulations and experimental testing on anisotropic carbon fiber reinforced polymer (CFRP) laminates. We demonstrate that the proposed algorithm successfully compensates for the processing artifacts and enhances the overall quality of the wavenumber maps facilitating unequivocal damage detection.

High-resolution defect imaging of composites using delay-sum-and-square beamforming algorithm

Abstract High-resolution ultrasonic imaging for defects in anisotropic multilayer carbon fiber reinforced polymers (CFRPs) is challenging because of the severe ultrasonic attenuation and the low signal-to-noise ratio (SNR) of echoes. The existing delay-multiply-and-sum (DMAS) beamforming outperforms delay-and-sum (DAS) beamforming in resolution, but with high computational complexity and energy loss. This paper presents a novel delay-sum-and-square (DSAS) beamforming algorithm. It takes full advantage of spatial coherence of captured data in the receiving and transmitting apertures. The non-coherent components caused by background noise are suppressed during the imaging. The back-wall reflection method (BRM) is used to correct the direction-dependent velocity. Full-matrix data is experimentally captured and processed on three different CFRP samples. Compared with DAS and DMAS, DSAS has a significant improvement in resolution, SNR and contrast. It demonstrates excellent defect characterization and noise suppression capability with only 17.4% computation time of DMAS.

Evaluation and optimization of flexural properties of anisotropic recycled carbon fiber card web reinforced thermoplastic hollow beams

The flexural properties of hollow beams are influenced by both the structural morphologies and the level of anisotropy of the materials. Card web carbon fiber-reinforced thermoplastics (CWTs), recognized as a promising composite for fabrication with recycled carbon fiber, demonstrate control over fiber alignment and robust mechanical properties, characterized by a wide distribution of fiber lengths. In this study, square-shaped, tube-shaped, and hat-shaped hollow beams are modeled with different geometries. Calculations are performed on different input data featuring CWTs with varying fiber alignments using a modified Mori-Tanaka model, and the results are verified with experimental data. The effects of fiber alignment, beam geometries, and beam types on the flexural properties of CWT hollow beams are evaluated and compared with unidirectional (UD) carbon fiber composites, aluminum alloys, and steel beams. The highest levels of flexural stiffness and specific flexural stiffness (indicative of the most effective lightweight property) in square-shaped and tube-shaped hollow beams were observed in CWTs with higher fiber alignment. The hat-shaped beams achieved the highest level of flexural properties at a relatively lower fiber alignment level. Comparisons with 1 mm wall-thickness steel hollow beams indicated that CWTs with specific fiber alignments could achieve a weight reduction of over 50 % while maintaining the same flexural stiffness. This performance surpasses that of UD composites and aluminum alloys.

Thermal performance of phase change materials with anisotropic carbon fiber inserts

In thermal energy storage systems, phase change materials (PCMs) are widely used for thermal energy management. Most PCMs have low thermal conductivities, which limits the heat transfer rate within PCM and thus makes the phase-changing process very slow. However, thermal conductivities of PCMs can be altered by inserting targeted additives. We hypothesize that the size and shape of these additive inserts play a key role in thermal management efficiency. To this end, the impacts of carbon fiber (CF) inserts on the phase change behavior and consequent heat transfer efficiencies of inorganic and organic PCMs were investigated using experiments and simulations. Long, anisotropic CFs with high thermal conductivities formed continuous fast heat flux tunnels inside PCMs to enhance the heat transfer. Such CFs could extend the phase change fronts from the limited container-shaped interface to the larger surface of numerous CF inserts inside the PCM. These special CF inserts work with a new heat transfer mechanism, different from conventional small additives or long isotropic CF inserts. The thermal energy release rate increased by 2.5 times with 1 wt.% anisotropic CF inserts in inorganic PCM. However, CF inserts in liquid organic PCM hindered the natural convection and compromised the improved heat conduction. The lab-scale multiphysics simulations support these experimental observations and indicate that CF inserts have potential to enhance heat transfer in inorganic PCMs, but they are less effective in organic PCMs.

Thermal rounding for shape modification of high-performance polyetherketoneketone and reinforced polyetherketoneketone-carbon fiber composite particles

This study presents shape transformation of anisotropic high-performance thermoplastic polyetherketoneketone (PEKK) and carbon fiber reinforced powder composite particles (HT-23) by thermal rounding. The shape transformation is achieved by (partial) melting of the high-temperature thermoplast microparticles. Three different process setups are presented, investigating the impact of the source of heat supply on the resulting shape modification: using a directly heated sheath gas flow, an indirect heat supply through the reactor wall and a combined approach. Regardless of the chosen setup, a modification of the particle shape was observable. The most advantageous shape transformation was observed in the indirect heating approach. In addition, the enhanced shape transformation yields an improved free flow behaviour of the powders, as quantified by ring-shear experiments. Reductions of the unconfined yield strengths of the powders for high consolidation stresses as high as 18 percent for PEKK and 30 percent for the HT-23 are achieved. Thereby, processability of the powder in laser based powder bed fusion is enhanced, extending the range of available (composite) polymer materials.

Guided wave propagation and skew effects in anisotropic carbon fiber reinforced laminates

Guided ultrasonic waves provide a promising structural health monitoring (SHM) solution for composite structures as they are able to propagate relatively long distances with low attenuation. However, the material anisotropy results in directionally dependent phase and group velocities, in addition to energy focusing, wave skewing, and beam spreading phenomena. These effects could lead to inaccurate damage localization if not accounted for. In this contribution, the guided wave propagation behavior (A0 mode) for a highly anisotropic, unidirectional carbon fiber reinforced polymer laminate is systematically investigated through both finite element analysis and non-contact laser measurements and compared to theoretical predictions. The directional dependency of phase and group velocity measured for a point and line source shows good agreement with theoretical predictions, once a correction for wave skew effects is applied. Wave skew angles were evaluated from the experimental and numerical wave propagation in multiple directions and matched theoretical predictions based on the phase slowness curve. Significant guided wave beam spreading from a line source was observed and quantified from both experiments and simulations and compared with theoretical predictions using the anisotropy factor. The impact of anisotropic guided wave propagation behavior on SHM is discussed.

Biotissue‐Inspired Anisotropic Carbon Fiber Composite Hydrogels for Logic Gates, Integrated Soft Actuators, and Sensors with Ultra‐High Sensitivity (Adv. Funct. Mater. 11/2023)

Thermo-Responsive Actuators In article 2211189, Jun Fu and co-workers study carbon fiber composited hydrogels that show extremely high anisotropy in mechanical properties, conductivity, and sensitivity. Twisted carbon fibers inside the hydrogels motivate thermo-responsive actuation, which can be self-monitored. The anisotropic hydrogels also demonstrate applications for “AND” or “OR” logic gates.

Biotissue‐Inspired Anisotropic Carbon Fiber Composite Hydrogels for Logic Gates, Integrated Soft Actuators, and Sensors with Ultra‐High Sensitivity

AbstractNatural biotissues like muscles, ligaments, and nerves have highly aligned structures, which play critical roles in directional signal transport, sensing, and actuation. Inspired by anisotropic biotissues, composite hydrogels with outstanding mechanical properties and conductivity are developed by compositing thermo‐responsive poly (N‐isopropylacrylamide) (PNIPAM) hydrogels with highly aligned carbon fibers (CFs). The anisotropic hydrogels show superior tensile strength (3.0 ± 0.3), modulus (74 ± 7.0 MPa), excellent electrical conductivity (≈670 S m−1), and ultra‐high sensitivity (gauge factor up to 647) along CFs, with an anisotropic ratio (AR) up to 740 over those in perpendicular direction. The extremely high AR in conductivity (more than 400) produces high‐level output in parallel direction and low‐level output in perpendicular direction with a direct current (DC) power supply, which is used to fabricate AND and OR gates. Moreover, the composite hydrogels are converted into thermo‐responsive actuators with CFs twisted before compositing with PNIPAM/clay network. The pre‐twisted CF helices impart internal stress that drives reversible actuation of hydrogel helices upon thermo‐stimulating. The actuation is self‐sensed due to the extremely high sensitivity of the composite hydrogels. Such biomimetic anisotropic self‐sensing hydrogel actuators resemble natural biotissues with both actuation and sensing capabilities, and have promise applications for artificial robotics.

Exploration of the effect of wing component post-buckling on bending-twist coupling for nonlinear wing twist

A new investigated concept for passive load alleviation is to exploit the nonlinear behavior of wing design components to trigger a deformation which reduce loads once a critical load level is reached. The necessary deformation is a torsional rotation which is supposed to reduce the angle of attack. For this target, wingbox sections are investigated regarding their nonlinear behavior with finite element analysis. Parameter studies feature anisotropic carbon fiber reinforced polymer (CFRP) layups for the skins, layups and thicknesses for spars and the presence of stringers. Results show a desired nonlinear progressive bending-torsion coupling for an unstiffened wingbox section, when the upper skin and the rear spar are modified. After modification they are allowed to buckle within the load envelope. The skin has an anisotropic layup. The rear spar needs to be thinner than the front spar. Both modifications result in progressively increasing torsional rotation of the wingbox with increasing load. Stringers are not applied because they limit the nonlinearity which is not desired for the envisioned load alleviation technique.

External field alignment of nickel-coated carbon fiber/PDMS composite for biological monitoring with high sensitivity

Abstract Flexible, pressure-sensitive composites can be prepared through the inclusion of electrically conductive particles as functional fillers into an elastomeric polymer matrix, which have been used for the applications of wearable devices for health monitoring and electronic skins. A key challenge associated with these composites is developing anisotropic pressure sensitivity while retaining their flexibility (or low filler content). Herein, we demonstrate a simple and scalable method for aligning anisotropic nickel-coated carbon fibers (NiCF) along with the thickness direction of a polymer matrix by applying a magnetic field. The aligning mechanisms and kinetics of NiCF in the polydimethylsiloxane (PDMS) precursor are revealed by in situ optical microscopy images while a magnetic field is applied. The aligned nickel-coated carbon fibers in the polymer effectively endow the composite films excellent pressure-sensitive performance. The pressure sensitivity of NiCF/PDMS composite films has been systematically studied and can be used for biological monitoring. We believe that this magnetic field assisted processing strategy provides a promising material solution for manufacturing fiber embedded polymer composites with enhanced pressure sensitivity, which is essential for future wearable health monitoring electronics and electronic skin.

Three Stages of Composite Specimen Destruction in Static Failure

Abstract The paper presents the results of standard specimen fracture made of anisotropic carbon fiber plastic with an epoxy matrix. Static stepwise loading of the specimen was carried out on an Instron 8801 testing machine to determine the characteristics of ductile fracture G1C in the first mode in accordance with ASTM D5528. During loading, the parameters of acoustic emission (AE) signals, such as AE impulse amplitudes and their energy were synchronously recorded. At the same time, the magnitude of the opening and the growth of the crack initiated by the artificial cut at the end of the specimen were recorded. According to the analysis of the acoustic emission signals, three zones with different G1C behaviour were identified: initial crack propagation, its stationary growth and accelerated fracture of the specimen. The zonal character of the change in the acoustic emission signals made it possible to determine the energy of the acoustic emission signals as diagnostic evidence for the onset of rapid destruction of the specimen. The amplitude of the AE-signals in the zones, however, remained constant. Online monitoring of changes in the energy of acoustic emission signals will prevent the onset of rapid destruction of an object in places of its deformations. The paper does not aim at defining G1C as usual. It presents the investigation of the fracture stages for a composite material using an acoustic emission method.

Analysis on ultrasonic waves generated in anisotropic carbon fiber reinforced plastic laminate by laser incidence from various directions

Laser-ultrasonic waves are used in nondestructive inspections because they can be excited on arbitrarily shaped surfaces by irradiation of a pulsed laser from a distance. During the non-contact scanning of a laser, the waveform of excited ultrasonic wave is changed because the incident angle varies substantially. The change of the waveform will be more obvious for carbon fiber reinforced plastics (CFRP) laminates that have anisotropic properties. In order to guarantee the inspection, in this paper, we investigated the generation of ultrasonic waves in CFRP laminates by a laser irradiation with various incident angles and azimuth angles. Firstly, we constructed a simulation model: the thermal force field caused by the laser absorption is derived from a heat conduction equation, and it is introduced into an FEM software for analyzing the propagation behavior of generated ultrasonic waves. Then, the simulation result is compared with an experiment result. Through the FEM analysis, we found that the amplitude of the excited waves has an obvious directivity because of the strong anisotropy in the thermo-elastic property of the CFRP. In addition, the change in propagation behavior in the case of a small incident angle of 30° was found to be inconspicuous. However, when the incident angle of the laser beam is larger than 60°, the directivity pattern changes depending on the azimuth angle. Thus, it is important to control the incident angle and direction when a laser ultrasonic inspection is applied to CFRP structures.

Acoustic emission monitoring of composite specimens with impact damage during static compression test

The standard specimens have been made by anisotropic carbon fiber plastic with an epoxy matrix. The specimens were subject to static load after its shock impact. During static compression loading, the parameters of acoustic emission (AE) signals were synchronously recorded: AE impulse amplitudes, its energy and the number of oscillations. According to the analysis of the acoustic emission signals the following events were observed: matrix cracking, fiber delamination and fiber destruction. The character of the AE signals change made it possible to determine the energy of the acoustic emission signals as a diagnostic witness of the onset of two moments of the specimen destruction. The first = near 70% of ultimate load’s (the destruction of matrix) and total destruction under ultimate static load.

Deep learning for impact detection in composite plates with sparsely integrated sensors

In this paper, both location and energy of impacts on an anisotropic carbon fiber reinforced plate (CFRP) are detected with the help of deep learning. We introduce sparse low-cost sensor array integration in CFRP plates that allows for structural monitoring of lightweight structures. Using a resin transfer moulding process microelectromechanical systems (MEMS) and piezoelectric transducers (PZT) sensors are integrated into CFRP plates. We developed an automated test bench to perform weight drop impact loadings with impact energies ranging between 0.22–0.56 mJ on a 1 × 1 cm2-grid with 441 locations. The obtained sensor signals were processed by means of a short-time fourier transformation and used as input for the training of a deep learning model. This model was implemented with a convolutional neural network. To accelerate the training phase we introduce a coarse analytical model that generates artificial sensor signals we use for pretraining of the neural network. Yielding high prediction accuracies of 99.82% and 98.68% for a correct classification of impact location and energy, respectively, the capability of the proposed approach was demonstrated. Despite their limited resolution the low-cost MEMS accelerometers were able to correctly locate an impact and its energy with 99.76% and 97.04%, respectively. The pretraining led to an increased robustness of the training process. Additionally, for the case of PZT sensors, it also reduced the number of required epochs for convergence significantly.

Modeling the Compressive Buckling Strain as a Function of the Nanocomposite Interphase Thickness in a Carbon Nanotube Sheet Wrapped Carbon Fiber Composite

Polymer matrix composites have high strengths in tension. However, their compressive strengths are much lower than their tensile strengths due to their weak fiber/matrix interfacial shear strengths. We recently developed a new approach to fabricate composites by overwrapping individual carbon fibers or fiber tows with a carbon nanotube sheet and subsequently impregnate them into a matrix to enhance the interfacial shear strengths without degrading the tensile strengths of the carbon fibers. In this study, a theoretical analysis is conducted to identify the appropriate thickness of the nanocomposite interphase region formed by carbon nanotubes embedded in a matrix. Fibers are modeled as an anisotropic elastic material, and the nanocomposite interphase region and the matrix are considered as isotropic. A microbuckling problem is solved for the unidirectional composite under compression. The analytical solution is compared with finite element simulations for verification. It is determined that the critical load at the onset of buckling is lower in an anisotropic carbon fiber composite than in an isotropic fibfer composite due to lower transverse properties in the fibers. An optimal thickness for nanocomposite interphase region is determined, and this finding provides a guidance for the manufacture of composites using aligned carbon nanotubes as fillers in the nanocomposite interphase region.

Locating Defects in Anisotropic CFRP Plates Using ToF-Based Probability Matrix and Neural Networks

This paper presents two algorithms, both based on the time of flight (ToF) of scattered waves, to locate defect in an anisotropic woven-fabric carbon fiber reinforced polymer (CFRP) plate. The first algorithm uses a probabilistic approach by constructing a probability matrix. Each element of this matrix is associated with a location and represents the probability of existing a defect at the corresponding spatial coordinates of the plate. For the probability matrix method, localization results are influenced by manually chosen parameters and by the anisotropy of the CFRP plate. The second algorithm, based on artificial neural networks (ANNs), enables us to improve the accuracy of locating defects. With this ANN method, the anisotropic feature can be “learned” by the neural network from training data. The ToF of scattered waves obtained from three sensor pairs were used directly as inputs of the neural network. The spatial coordinates of the defect are the ANN outputs. The difficulty of obtaining sufficient experimental data for ANN training was surpassed by using added blocks on the surface of the plate under test to simulate defects. This scheme was validated and proved to be effective by comparing the scattered waves from a delamination and from an added block. Conclusions have been drawn by comparing the two methods. The localization results obtained by the ANN algorithm are proved to be better.

3D Printing of Mechanically Anisotropic Carbon Fiber Reinforced Plastic

3D Printing of Mechanically Anisotropic Carbon Fiber Reinforced Plastic

A mixed-form solution to the macroscopic elastic properties of 2D triaxially braided composites based on a concentric cylinder model and the rule of mixture

Understanding the elastic properties of 2D triaxially braided composites (2DTBCs) is fundamental for further analysis and design of structural components made from 2DTBCs. Based on a concentric cylinder model (CCM) and the rule of mixture (RoM), we reformulated the global stiffness of 2DTBCs for the anisotropic carbon fiber reinforcement to replace the currently available formulations for the isotropic glass fiber reinforcement with a replacement scheme. First, the global stiffness calculated from CCM, Quek's model and Shokrieh's model was compared for clarification. It was found that Shokrieh's model had the relatively worse performance under the same conditions. Second, the performances of Shokrieh's model, CCM, Quek's model and CCM+RoM (Reuss-type and Voigt-type) were compared using available experiments under various braiding configurations and our experiments on the hybrid carbon/glass fiber reinforced 2DTBCs, which revealed that Quek's model and CCM+RoM (Reuss-type) could yield equivalently great results, and CCM+RoM (Reuss-type) performed even better in some cases.

Application of electrical impedance tomography to an anisotropic carbon fiber-reinforced polymer composite laminate for damage localization

Electrical impedance tomography (EIT) is an emerging method for assessing the structural condition of composite structures. In this work, EIT's damage localization capability is investigated through its application upon a commercial laminated anisotropic carbon fiber reinforced polymer plate. Aluminum rivets were used as electrodes. EIT reconstructs the spatial conductivity within a defined space by using its boundary voltage response. The algorithm starts with a forward simulation of the voltage distributions within the boundary, hence the orthotropic conductivity of the CFRP plate was first characterized experimentally. It was found that the inhomogeneous fiber contacts through the thickness are influencing the reconstruction results. A detailed 3D finite element simulation was built to model the conductivity distribution. Different current injection patterns were attempted with their reconstruction results being evaluated via four criteria. It was found that the diagonal current injection and the difference evaluation lead to the best results.

Characterization of delaminations in composite laminates by laser ultrasonics

Abstract The influence of delaminations in the anisotropic carbon fiber reinforced plastics (CFRP) on laser- generated ultrasound is investigated. A 3D-finite element method is used to simulate the propagation of ultrasonic waves in CFRP with delaminations. The asymmetric properties and distortions as well as the wave reflection and attenuation at delamination interfaces are clearly shown. Measurements on CFRP specimens with circular delaminations above 2 mm in diameter are imaged by C-scans and correlated to the modeling results. The effects of ultrasound frequency, defect size and depth location are discussed. The results show that it is possible to decrease the influence of anisotropy in CFRP composites by choosing appropriate ultrasonic frequencies and controlling the laser parameters.