Carbon Fiber Composite Materials Research Articles

Application of carbon fiber composite materials in aircraft

Carbon fiber composite is a material with excellent mechanical properties. Compared with other high-performance fiber materials, carbon fiber composites have the advantages of high strength and high modulus even at ultra-high temperatures. In addition, the carbon fiber composite material also has excellent electrical and thermal conductivity and electromagnetic shielding performance. Carbon fiber composites are widely used in the aircraft manufacturing industry due to their incomparable performance with other composite materials. In recent years, the amount of carbon fiber composite materials in newly developed aircraft products has reached more than 50%. This paper aims to explore the application of carbon fiber in aircraft, and to reflect the importance of carbon fiber composite materials by comparing models that use composite materials and models that do not use composite materials. The study explores the application of carbon fiber composite materials in aircraft through a comprehensive literature analysis and review. Key findings indicate significant advantages of these materials in enhancing aircraft performance, including reduced weight and increased strength. The paper also discusses the challenges in manufacturing and environmental impacts, offering insights into future research directions for sustainable aviation technologies.

3D printing path method for multi-tow continuous carbon fiber

Carbon fiber composite materials have many excellent characteristics such as high temperature resistance, friction resistance, thermal conductivity and corrosion resistance, so carbon fiber composite materials have become the first choice for printing materials. In order to improve the printing efficiency of carbon fiber 3D printing technology, it has been expanded to four side-by-side nozzles based on traditional single nozzles, and four nozzles are bound to print side by side. The four-nozzle side-by-side printing path has the problem of coordinating the motion planning of each nozzle, controlling the squeezing difference of each nozzle, and adjusting the angle of the print head, so it is necessary to reasonably control the squeezing amount of each nozzle and the angle of the print head. After the slicing processing based on the existing model, the Gcode code of the model is obtained. The Gcode code of the model is processed through the multi-tow continuous carbon fiber 3D printing path planning algorithm. The movement trajectory of each nozzle of the printer is reasonably planned based on the outer wall coordinates and the extrusion amount of each nozzle is controlled. Finally, the snipping instruction is executed after a circle of trajectory to print the next layer of motion trajectory, which ultimately improves the 3D printing while ensuring the accuracy of multi-beam model 3D printing.

5G-enabled, battery-less smart skins for self-monitoring megastructures and digital twin applications.

With the current development of the 5G infrastructure, there presents a unique opportunity for the deployment of battery-less mmWave reflect-array-based sensors. These fully-passive devices benefit from having a larger detectability than alternative battery-less solutions to create self-monitoring megastructures. The presented 'smart' skin sensor uses a Van-Atta array design enabling ubiquitous local strain monitoring for the structural health monitoring of composite materials featuring wide interrogation angles. Proof-of-concept prototypes of these 'smart' skin millimeter-wave identification tags, that can be mounted on or embedded within common materials used in wind turbine blades, present a highly-detectable radar cross-section of - 33.75 dBsm and - 35.00 dBsm for mounted and embedded sensors respectively. Both sensors display a minimum resolution of 202 -strain even at 40 off-axis enabling interrogation of the fully-passive sensor at oblique angles of incidence. When interrogated from a proof-of-concept reader, the fully-passive, sticker-like mmID enables local strain monitoring of both carbon fiber and glass fiber composite materials. The sensors display a repeatable and recoverable response over 0-3000 -strain and a sensitivity of 7.55 kHz/ -strain and 7.92 kHz/ -strain for mounted and embedded sensors, respectively. Thus, the presented 5G-enabled battery-less sensor presents massive potential for the development of ubiquitous Digital Twinning of composite materials in future smart cities architectures.

A study on the strand arrangement in 3D printing of continuous carbon fiber composite materials with multiple strands

3D printing of continuous carbon fiber composite materials with multiple strands has significant potential for improving model forming efficiency. However, in this field, we are faced with the challenge of arranging multiple fiber strands closely without excessive overlap consolidation, to avoid damage to the original model. The inability to effectively control the arrangement of multiple strands can significantly affect the print accuracy and mechanical performance of the model. Therefore, in this study, a predictive formula for the line width of carbon fiber strands is first presented. Subsequently, a device dedicated to 3D printing with multiple strands is designed using this formula, and the interrelationship between pressure and the arrangement of multiple strands is delved into. Comparative tests are also conducted on printed parts for tension and bending to investigate the influence of strand arrangement tightness on the mechanical performance of printed samples under different pressure conditions. Through electron microscopy experiments to analyze the microstructure of fracture surfaces, the causes of differences in mechanical performance and the potential effects of different pressures on print accuracy are explained. The results of the study indicate that when pressure can be precisely controlled to ensure a tight arrangement between multiple strands, the mechanical performance of printed parts reaches its optimal state. The tensile strength can reach 360.62 MPa, and the bending strength is 311.04 MPa. At the same time, for test samples printed under the optimal printing pressure, their surface accuracy is also at its best.

PECT Composite Defect Detection Algorithm Based on DualGAN

To address the problems of insufficient accuracy and slow reconstruction speed of Planar Electrical Capacitance Tomography (PECT) detection of damaged specimens, a Dual Generative Adversarial Networks (DualGAN)-based PECT image defect detection method is proposed in this paper. The improved particle swarm algorithm with adaptive particle number and L2-norm is used to optimize the sensitivity field, combined with the parallel Landweber algorithm to solve the PECT inverse problem to obtain the dielectric constant distribution map. In the DualGAN network, the Unet generator utilizes an Adam-based local attention mechanism to adjust module weights, facilitating feature extraction and the generation of high-quality transformation images of the Landweber dielectric constant distribution. A PatchGAN discriminator is employed to distinguish between transformation images and real images, using the generated transformation images as target images. Experimental results demonstrate that the sensitivity field, enhanced by the improved particle swarm algorithm and L2-norm normalization, achieves better balance. Furthermore, the addition of a network transformation using the Adam-based local attention weight mechanism on the DualGAN network reduces artifacts in the reconstructed images, resulting in more accurate PECT reconstructions. The PECT image defect detection method, integrating DualGAN, an improved particle swarm optimization algorithm, and a local attention mechanism, has made significant strides in addressing challenges related to image reconstruction accuracy and speed. This technological advancement has enhanced the precision and efficiency of defect detection in carbon fiber composite materials, thereby fostering the broader utilization of planar capacitance tomography technology in industrial damage detection and material defect analysis.

Modeling and Programming of a Spiral Winding Cycle Using a Robotic Arm

This article is devoted to solving the problem of manufacturing products from carbon fiber composite materials, which are obtained as a result of layer-by-layer laying of carbon fiber with impregnation of their binder components. This paper presents a description of the process of spiral winding of products on a cylindrical mandrel and the mathematical model, which takes into account the coefficient of friction and the necessary reverse zones in which the tape will not slip. The model is implemented as a Python program and is capable of simulating and visualizing the step-by-step winding of a carbon tape on a cylindrical surface. It is possible to optimize the friction coefficient to ensure the tightest winding of subsequent passes. The program takes into account reverse zones, which are calculated taking into account the friction coefficient of the cylindrical mandrel. Based on the simulated winding process, a control program for the robotic arm is generated. The performance of the proposed model and its implementation was tested on a test bench with a robot.

Designed MoSe2 modified multi-layer hollow carbon fiber composite material achieves tunable electromagnetic wave absorption in the X and Ku bands

As a substitute for graphene-based carbon materials, carbon fiber (CF) based absorbing materials have enormous application prospects. Effective improvements have been made in solving the problems of heavy quality and complex preparation processes of ordinary absorbing materials. In order to obtain a flexible thin fiber membrane absorbing material with good stability and excellent performance, we prepared a multi-layer hollow carbon sphere/CF@MoSe2 with carbon fiber as the matrix, and controlled the microstructure through hollow carbon shell and MoSe2, and introduced transition metal chalcogenides to coordinate electromagnetic parameters. As a result, the hollow carbon sphere/CF@MoSe2 flexible composite film achieved a minimum reflection loss (RLmin) of −47.98 dB at a thickness of 2.5 mm, and an effective bandwidth (EAB) of 8.1 GHz at a thickness of 2.7 mm. The RLmin of the hollow carbon ball/CF composite film reached −45 dB at a thickness of 2.6 mm, and the EAB reached 3.2 GHz. The theoretical characterization results jointly prove the reason for the improved performance, and this study provides an experimental basis for a more in-depth exploration of the birth of new absorbing materials.

Comparative life cycle assessment of aluminium and CFRP composites: the case of aerospace manufacturing

As climate change intensifies and existing resources are depleted, the need for sustainable industries becomes more important. The aviation industry is actively addressing environmental concerns by enhancing fuel efficiency and adopting lighter materials, especially carbon fibre composites. Research has proven that the use of carbon fibre composites provides cumulative benefits in reducing fuel consumption over the entire life cycle of an aircraft. However, existing studies are lack of a comprehensive exploration of the diverse impacts associated with composite manufacturing processes and recycling methods. To address this gap, a comparative life cycle assessment analysis covering the materials’ manufacturing, operation, and end-of-life phases is conducted. This analysis includes aluminium alloy and five different carbon fibre composite materials produced with varied constituents and manufacturing methods. Composite manufacturing processes, encompassing carbon fibre production, resin selection, and composite manufacturing methods, are considered. Weight savings based on the mechanical properties of utilised composite type are also taken into account. Results highlight the potential to mitigate the environmental impact of composite materials through strategic choices in constituent types, manufacturing processes, and disposal scenarios. Moreover, break-even distances indicate that aluminium becomes more environmentally detrimental than the analysed composite structures beyond a flight distance of 300,000 km.

The Influence of Variable Stiffness of the Shape Memory Alloys Carbon Composite Structure on Mechanical Vibration.

The purpose of this study is to investigate the dynamic properties of new structures formed by combining carbon fiber and epoxy resin-based composite materials with SMA (shape memory alloy) "smart materials" in the form of NiTiNol wire. Such a combination will have an impact on the dynamics of the structure, especially in terms of stiffness controllability. Key mechanical parameters such as natural frequency and stiffness, as well as the effect of temperature, were determined through experimental studies.

Enhanced interfacial and mechanical properties of carbon fabric/PA12 composites via grafting silanized nano hexagonal boron nitride onto the fibers

ABSTRACT The purpose of this work was to create thermoplastic composites based on carbon fiber fabric reinforced enhanced mechanical and interfacial properties, based on PA12 (polyamide 12). In line with these objectives, it is aimed to develop carbon fiber reinforced thermoplastic composite materials with improved interfaces by sizing chemical modification and interfacial compatibility suspension development using hBN (hexagonal boron nitride) nanomaterial. The production of bare and silanized hBN sizing grafted CF (carbon fiber)-PA12 plates was followed by various mechanical, thermal, and SEM analyses. When the mechanical test results of CF-PA12 and hBN-APTES (3-Aminopropyltriethoxysilane) Sizing Coated Composite Specimens are compared; it is proved that hBN-APTES sizing improves the mechanical properties. Furthermore, sizing coated CF-PA12 composite specimens showed improvements in flexural strength of 20.67% and compressive strength of 19%, respectively. The significance of these results is to enhance the critical interfacial properties in the manufacturing of carbon fiber composite materials based on PA12, and to produce high-quality products that can be used in a variety of industries, including sports equipment, automotive, and aerospace, all of which have a constant demand worldwide.

Heat-resistant carbon fiber composite materials based on fusible oligoimide

In this work, oligoimide powder binders of the IDA type based on 4,4’-’oxydiphthalic anhydride and bis-(4-acetamido)diphenyl oxide with different molecular weights were obtained. CFRPs were obtained by electrostatic spraying of a powdered oligoimide binder onto a carbon fabric, followed by high-temperature calendering and hot pressing of prepregs. The thermal and mechanical characteristics of the obtained carbon composites are determined.

Experimental study on the combustion characteristics of carbon fiber composite materials coated in different coatings

The special environment in which the aircraft operates in terms of flight and safety assurance has special requirements for coating performance. Based on the combustion characteristics of four kinds of high-performance aviation coatings coated with carbon fiber composites, for parameters such as average ignition time and heat release rate of the composite, the results show that the carbon fiber composite has the longest average ignition time, Minimum heat release rate, while the 2-ethyl-4-Mylimidazole cured epoxy coated fiber composite had the shortest average ignition time. The maximum heat release rate was observed.

High injection molding welding strength and cross-sectional analysis of carbon fiber composite materials

In this study, carbon fibers, commonly used as reinforcement materials, were added to polyamide (nylon) PA6 to fabricate carbon fiber-reinforced thermoplastic composites (CFRTP), which were then subjected to injection molding welding. The aim of this research was to investigate the positive influence of carbon fibers on injection molding welding strength and explore the optimal injection conditions. Three different joining combinations and various injection parameters were examined. The tensile fracture surfaces after welding were observed using polarized microscopy and scanning electron microscopy. The reinforcing mechanism of carbon fibers was analyzed. Ultimately, the optimal conditions were determined as a mold temperature of 120°C, an injection temperature of 380°C, and an injection velocity of 150 mm/s. The addition of carbon fibers exhibited significant strengthening effects on the injection molded joints, and it also provided the potential for injection molding welding between resins with poor compatibility.

Research on the lightweight design and multilevel optimization method of B‐pillar of hybrid material based on side‐impact safety and multicriteria decision‐making

AbstractThis paper designs and optimizes a new structure hybrid material B‐pillar assembly. Establish a finite element analysis model for the side impact test of an electric vehicle to verify the model's accuracy. Construct a finite element model of the hybrid material B‐pillar assembly. Combined with the static performance analysis of the B‐pillar, the laminate design of the carbon fiber composite B‐pillar reinforcement plate and optimization. For the outer and inner panels of the B‐pillar, the surrogate model method and the multiobjective optimization method are combined to set 11 design variables and 13 responses. The optimal Latin hypercube design method was used to randomly sample each design variable and fit the radial basis function (RBF) approximate model. The modified second‐generation non‐dominated sorting genetic algorithm (MNSGA‐II) was used to carry out multiobjective optimization of the mixed material B‐pillar assembly, and the multicriteria decision‐making method was used to obtain the optimal solution for the Pareto solution set. A drop weight impact test was performed on the hybrid material B‐pillar assembly. The results showed that the peak collision force of the hybrid material B‐pillar was reduced by 43.7% compared with the original steel B‐pillar, the specific energy absorption was increased by 17.5%, and the side impact safety performance was better. After optimization, the weight of the mixed material B‐column was reduced by 26.44%. The improvement rates of the intrusion amount at P2 and the intrusion speed at P1 were 23.99% and 0.63%, respectively, and the lightweight effect and side impact safety were significantly improved.Highlights The finite element analysis parameters of carbon fiber composite materials were constructed through experiments, and the basis for simulation analysis under various working conditions of the B‐pillar based on performance‐driven optimization was established. A hybrid material B‐pillar design method is proposed, which consists of a variable‐thickness high‐strength steel B‐pillar outer plate, a variable‐thickness high‐strength steel B‐pillar inner plate, and a carbon fiber composite B‐pillar reinforcement plate. The super layer of the carbon fiber composite B‐pillar reinforcement plate was optimized and the laying plan of the carbon fiber composite B‐pillar reinforcement plate was determined. Performance‐driven optimization is adopted to realize the collaboration of multilevel design and optimization methods such as B‐pillar conceptual design, detailed design, and multiobjective optimization. A modified NSGA‐II algorithm was proposed and combined with the multicriteria decision‐making method and the entropy‐weighted gray relation analysis method to determine the Pareto optimal solution and the optimal design scheme for the mixed material B‐pillar.

Material choice to optimise the performance index of isogrid structures

Three key qualities should define the structures used in the aviation industry: they should be light, rigid, and strong. These goals can be met by selecting lightweight, high-performance materials like titanium alloy or composites, but careful structural design is also crucial to improve mechanical performance. The structures known as isogrids, which consist of a skin reinforced by a lattice frame, offer an effective way to meet the aforementioned specifications. The structural performances of isogrid-stiffened cylinders composed of various materials were compared in the current work. The structures under investigation were composed of titanium alloy, carbon fibre composite material, or a combination of both. A FEM model was proposed and validated by comparison with experimental results obtained from a composite material structure, and then it was used to simulate the behaviour of all the other structures. While there was some variation in the strength of the parts, it was discovered that the stiffness was almost uniform throughout all of the structures that were examined. But when the weight of the various constructions was taken into account, some very intriguing findings emerged: the composite material-only structure proved to be the most effective because it had the highest specific performances.

Tailoring fractal structure via 3D printing to achieve flexible stretchable electrodes based on Ecoflex/CNT/CF

Flexible electrodes are crucial for the widespread application of flexible electronics. Flexible stretchable electrodes are a research hotspot for finding a solution for the inability of flexible electrodes to withstand large deformations. In this study, the suitability of silicone rubber (Ecoflex), carbon nanotube (CNT), and carbon fiber (CF) composite materials for flexible devices and their ratios were evaluated for the first time. 3D-printed electrodes based on fractal structures with tensile insensitivity and high linearity were prepared to achieve integrated stretching of flexible devices. To demonstrate the benefits and impact of fractal structures on electrode performance, we fabricated flexible stretchable electrodes with four distinct designs: horseshoe, U-shaped, rectangular, and triangular. The tensile properties of these structures were theoretically calculated and validated through simulations and experiments; the horseshoe design proved to be the softest. Furthermore, we evaluated the performance of the prepared third-order flexible stretchable electrodes for gas-detection applications and achieved promising results, demonstrating the significant potential of these electrodes for wearable gas detection.

Research of the thermal storage properties of thermally conductive carbon fiber-reinforced paraffin/olefin block copolymer composite phase change materials with thermotropic flexibility

This study focuses on the fabrication and evaluation of paraffin (PA)/olefin block copolymer (OBC)/carbon fiber (CF) composite phase change materials (CPCMs) prepared using the melt impregnation process. The resultant PA/OBC/CF CPCMs exhibit superior thermal stability below 200 °C and maintain excellent shape stability at 60 °C. These characteristics are attributed to the alternating soft and hard segments of OBC, wherein the hard segments prevent liquid leakage from PA. The distinct structure of OBC further lends flexibility and recyclability to the PA/OBC/CF CPCMs. The latent heat of these CPCMs ranges from 169.1 to 197.6 J/g. Notably, the CPCMs variant (PA/OBC/CF-1) with 2 wt% CF addition retains 95 % of its initial latent heat even after 100 thermal cycles, thereby demonstrating superior cycling stability. The thermal conductivity of CPCMs with 10 wt% CF is 1.3 times that of pure PA. This significant improvement in thermal conductivity is attributed to the heat conduction pathways provided by the fibrous CF. These results indicate that the fabricated CPCMs offer substantial promise for utilization in low-temperature waste heat recovery applications.

Ground testing of Al-polyurethane shape memory polymer sail material under pulsed light exposure

This article presents a study on design and testing of space sails using Al-polyurethane Shape memory polymer. The properties of the polymer are simulated and tested in the design phase, and the results are compared with the fabricated sail, which is considered nominal. The efficiency of the polyurethane sail is found to be approximately 86.5%. The controllability of the sail is enhanced using a heating system that uses light rays to heat the polymer at specific control spots. The relative deflection at these spots causes a deviation in solar momentum, resulting in a controlled displacement of the sail. This control system is found to be 42% more efficient than conventional vane-type deflection systems. The paper also presents the fabrication of a ground testing apparatus designed to test the sail specimen in laboratory conditions. The apparatus is capable of producing a vacuum chamber pressure up to −400 mm/Hg and includes a magnetic levitation platform with strong permanent magnets to neglect local gravitational effects. The platform provides support for fixing the solar sail frame made from carbon fiber composite material. The testing apparatus consists of a 1000-W halogen light source with intensity ranges of approximately 200,000 lux. Sail material with a reflective surface is exposed to controlled luminance under vacuum conditions to measure the deflection of the sail. Deflection values are recorded by means of a resistance type strain gauge and strain indicator arrangement. Plotting deflections with time period gives the acceleration of the sail inside the test apparatus. A coolant chamber with a ceramic base is also provided to reduce temperature effects inside the vacuum chamber. In conclusion, this study presents a promising approach for the design and testing of solar sails using shape memory polymer and a ground testing apparatus. The results of this research can contribute to the development of more efficient and versatile solar sail technology for fuel-free aerospace propulsion.

Carbon fiber comparison to traditional materials for the automotive industry

As automotive technology continues to advance; the industry is confronted with the ongoing challenge of improving car performance while maintaining safety and structural integrity. This long-standing challenge in the field of automotive technology may soon find a solution through the emergence of carbon fiber composite materials, potentially ushering in a new era of material dominance. Carbon fiber composites possess exceptional strength and extreme stiffness compared to metals, yet they exhibit a much lower density 80% less than steel. This unique combination of properties makes carbon fiber a possible alternative for automobile materials. Moreover, carbon fiber is a more sustainable material compared to traditional metals, offering environmental benefits. It also enables more efficient manufacturing techniques, contributing to reduced energy consumption and waste production. The present study investigates the feasibility of utilizing carbon fiber as the primary material for future automobiles, exploring the intricate aspects of its manufacturing process and examining the wide range of applications associated with this new material. By investigating carbon fiber's potential, the automotive industry could unlock many new opportunities for improved vehicle performance, fuel efficiency, and sustainability.

Strength and damage analysis of composite tube with metal lining

Based on the analysis of the structure and force characteristics of the composite tube, the feasibility of the finite element model is verified by conducting a quasi-static hydrostatic test on the new composite body tube combining carbon fiber composite material and metal lining, and comparing the ABAQUS finite element simulation to simulate the gradual damage and failure of the composite cylinder under hydraulic load. Based on the verified finite element model, the influence of single-angle spiral padding and multi-angle gradient spiral alternating padding on the pressure-bearing performance of composite tube is deeply explored, and the numerical analysis results show that the multi-angle gradient spiral lay-up method can make the composite tube show better performance. Based on the premise of this ply method, the univariate method was used to study the influence of carbon fiber grade on the pressure bearing performance of composite tube.