Carbon Fiber Composite Research Articles

Investigating the impact of extreme environments on the interlaminar performance of nanoparticle-reinforced carbon fiber composites

This study investigates the influence of extreme environmental conditions on the fracture toughness of halloysite nanotube (HNT)-reinforced carbon fiber-reinforced polymer (CFRP) composites. The focus is on the impact of exposure to high humidity and its effects on the mechanical properties of the composites. The study reveals that exposure to high humidity enhances the fracture toughness of HNT-modified CFRP composites, attributed to the entrapped moisture between HNTs and the polymer matrix. This phenomenon enhances crack bridging and contributes to improved mechanical properties. Furthermore, the HNT-modified composites exhibit superior environmental degradation resistance compared to unmodified composites, demonstrating the potential of HNTs as reinforcement for advanced composite materials. The investigation underscores the significance of considering environmental factors in nanoparticle-reinforced composite design and applications, paving the way for the development of durable, high-performance materials capable of withstanding extreme conditions. The findings emphasize the need for continued research to enhance the durability and reliability of such composites, thereby offering sustainable solutions across a range of applications. This study contributes valuable insights towards the design and optimization of fracture-resistant composite materials for demanding environments.

A novel approach to manufacturing high-performance reclaimed carbon fiber composites via convergent flow-induced discontinuous fiber aligned placement (CFi-DFAP)

As a low-cost and high-performance composite material, reclaimed carbon fiber (rCF) presents a practical and promising option. However, a challenge remains in controlling the fiber orientation of anisotropic rCF to exploit its outstanding properties fully. This study presents a novel method named Convergent Flow-induced Discontinuous Fiber Aligned Placement (CFi-DFAP) that reformats discontinuous fibers using convergent flow. The CFi-DFAP method enables the alignment and placement of rCF through an extrusion-deposition process. Experimental outcomes demonstrated that compared to random 6 mm-rCF and composites, aligned 6 mm-rCF and its composites exhibited substantial improvements in the preferential alignment degree, mechanical strength, and electrical conductivity. The CFi-DFAP approach paves the way to freely control the discontinuous fibers' orientation and placement position, potentially facilitating the design and manufacturing of high-performance discontinuous fiber composite.

Multifunctional Carbon Fiber Reinforced C/SiOC Aerogel Composites for Efficient Electromagnetic Wave Absorption, Thermal Insulation, and Flame Retardancy.

Carbon fiber composites have great application prospects as a potential electromagnetic (EM) wave-absorbing material, yet it remains extremely challenging to integrate multiple functions of EM wave absorption, mechanical strength, thermal insulation, and flame retardancy. Herein, a novel carbon fiber reinforced C/SiOC aerogel (CF/CS) composite is successfully prepared by sol-gel impregnation combined with an ambient drying process for the first time. The density of the obtained CF/CS composites can be controlled just by changing sol-gel impregnation cycles (original carbon fiber felt (S0), and samples with one (S1) and two (S2) impregnation cycles are 0.249, 0.324, and 0.402 g cm-3, respectively), allowing for efficient tuning of their properties. Remarkably, S2 displays excellent microwave absorption properties, with an optimal reflection loss of -65.45dB, which is significantly improved than S0 (-10.90dB). Simultaneously, compared with S0 (0.75 and 0.30MPa in the x/y and z directions), the mechanical performance of S2 is dramatically improved with a maximum compressive strength of 10.37 and 4.93MPa in the x/y and z directions, respectively. Moreover, CF/CS composites show superior thermal insulation capability than S0 and obtain good flame-retardant properties. This work provides valuable guidance and inspiration for the development of multifunctional EM wave absorbers.

A review of some new materials for lightweight and better performance purposes in vehicle components

Automobiles are the worlds primary way to travel, which leads to a constant race that automobile manufacturers are improving their vehicle performance by reducing weight. This paper introduces the values of density, yield strength, tensile strength, tensile modulus, flexural strength, and other properties of some new materials such as carbon fiber composite, magnesium alloy, aluminum alloy, high-strength steel, and carbon ceramic. Their drawbacks and advantages in vehicle industries and their potential development are presented in this paper.

Effectively improve the mechanical properties of carbon fabric/epoxy composites by oxidized carbon nitride

AbstractIn this work, carbon nitride (C3N4) powder was oxidized by the Hummers oxidation method, and oxidized carbon nitride (O‐C3N4) was obtained. Epoxy (EP) was modified with O‐C3N4, and then carbon fiber fabric/epoxy (CF/EP) composites were prepared by hand‐pasting molding. The O‐C3N4 greatly improves the wettability of EP resin, enhances the interface properties of CF/EP composites, and makes the composites have better mechanical properties. The interlaminar shear strength (ILSS) is increased from 51.75 to 59.68 MPa, the tensile strength is increased from 564.54 to 635.39 MPa, the bending strength is increased from 809.64 to 938.81 MPa, and the impact strength is increased from 73.48 to 84.84 kJ/m2. Meanwhile, the dynamic mechanical properties of composites are also significantly improved. The energy storage modulus is increased from 14.9 to 21.4 GPa, with an increase of 43.6%.Highlights Developing carbon fiber composites is conducive to industrial applications. O‐C3N4 effectively improves the mechanical properties of the composite. O‐C3N4 has the advantages of simple synthesis, low costs, and light color. O‐C3N4 is rich in oxygen‐containing functional groups.

Enhancing Carbon Fiber Properties through Lignin-Cellulose Composites: A Comparative Study of Hardwood Vs. Softwood Lignin Sources

Carbon fibers are integral to a wide range of applications, including automotive, construction, packaging, textiles, and emerging fields such as energy storage electrodes like flexible supercapacitors. However, concerns related to limited availability and environmental impact associated with fossil-based carbon fiber production have sparked growing interest in sustainable alternatives, particularly those derived from lignin and cellulose composites. This conference work presents a comparative analysis of the mechanical properties of lignin-cellulose composite carbon fibers derived from hardwood and softwood lignin sources, elucidating the significant influence of lignin origin on fiber performance.Our study focuses on the advantages and disadvantages of utilizing a composite of hardwood lignin vs. softwood lignin with cellulose in carbon fiber production, comparing these materials to commercially available carbon fibers. We emphasize the mechanical performance of these composite fibers, specifically highlighting the tensile strength and tensile modulus as a key metric. Notably, our results demonstrate that carbon fibers derived from hardwood lignin/cellulose composites exhibit superior mechanical strength compared to those from softwood lignin/cellulose composites. To gain fundamental insights into the reasons behind this mechanical disparity, we employed Raman spectroscopy to analyze the carbon structures within the fibers. Our findings revealed that carbon fibers produced from hardwood lignin exhibited a higher degree of graphitization, helping in achieving of typically desirable pre-graphite turbostractic carbon structures. These structural enhancements significantly contributed to the improved mechanical characteristics observed. In summary, our research underscores the critical importance of lignin source selection in the production of lignin-cellulose composite carbon fibers. The mechanical performance of these fibers is closely linked to the carbon morphology influenced by the lignin source. Therefore, understanding and controlling the lignin source from hardwood or softwood is pivotal for tailoring carbon fiber properties to meet specific application requirements. This study not only advances the knowledge in sustainable carbon fiber production but also offers valuable insights into achieving desirable properties for a wide range of applications, including advanced energy storage systems and structural materials.

Carbon nanofibers based carbon–carbon composite fibers

Textile grade polyacrylonitrile (PAN) was used as a precursor material for carbon fiber preparation. E-beam irradiated polyacrylonitrile grafted carbon nanofibers were dispersed in polyacrylonitrile solution (dissolved in dimethyl formamide). Carbon nanofibers (CNF) infused polyacrylonitrile solution was wet spun on a lab-scale wet-spinning setup to form 50 to 70 µm diameter fibers with 3.2 wt.% CNF-PAN, 6.4 wt.% CNF-PAN, and neat PAN. Precursor fibers were characterized for thermal, mechanical and morphological properties using various techniques. Drawing the precursor fibers further enhanced polymer chain orientation and coalesced the voids, enhancing tensile strength and modulus by more than 150% compared to those of the undrawn fibers. Precursor composite fibers on carbonization showed enhanced strength, compared to that of pristine PAN fibers, by four times and stiffness by 14 times. The carbon–carbon composite fibers were further characterized with SEM/FIB, XRD and tensile strength. The property improvements were dependent on the uniform distribution of carbon nanofibers, and surface modification of carbon nanofibers further enabled their dispersion in the composite fibers. Furthermore, 3.2 wt.% CNFs in PAN fibers showed maximum improvement in properties compared to 6.4 wt.% CNF in PAN fibers, indicating that the property enhancements go through a maximum and then drop off due to challenge in getting uniform distribution of nanofibers.

Preparation and sodium-ion storage performance of bimetallic oxygen sulfide composite hollow carbon fibers

Preparation and sodium-ion storage performance of bimetallic oxygen sulfide composite hollow carbon fibers

Tensile, impact, and the damping performance of woven flax‐carbon hybrid polyamide biocomposites

AbstractFiber hybridization is suggested to enhance the properties of fiber‐reinforced composites. Regarding the matrix, thermoplastic alternatives to conventional thermosets are needed to balance mechanical performance and sustainability. We combined woven flax and carbon fibers with a polyamide 11 matrix into a hybrid biocomposite and studied its manufacturing process as well as its impact, tensile, and damping properties. Mechanical damage was investigated using scanning electron microscopy and X‐ray computed tomography. Hybridization significantly improved the tensile properties: 233% higher modulus and 432% higher strength than pure flax composites and 19% higher failure strain than pure carbon composites. Additionally, the hybrid composites exhibited a positive hybrid effect with respect to the impact resistance, characterized by higher displacement at maximum impact force and occurrence of combined damage mechanisms. Although the damping behavior of the hybrid composites remained inferior to that of pure flax composites, their damping factor was 20% higher than that of pure carbon composites. These results provide valuable insights into the mechanical performance of carbon‐flax hybrid composites.Highlights Enhanced mechanical performance and impact resistance in woven flax‐carbon/PA11 hybrid biocomposite compared to nonhybrid reference composites. Superior tensile modulus and strength of hybrid biocomposite than pure flax fiber composite, and greater failure strain than pure carbon fiber composite. A positive hybridization effect in impact properties with a greater displacement at maximum force and higher dissipated impact energy, indicating enhanced ductility and fracture toughness. Improved damping behavior in hybrid biocomposite compared to the pure carbon composite.

Response and damage mechanism of carbon/aramid intra-ply hybrid weft-knitted reinforced composites under low-velocity impact

Carbon and aramid fiber hybridization is an effective method to improve the impact toughness of composites, thus this paper attempts to develop carbon/aramid hybrid weft-knitted reinforced composites to improve the impact resistance of carbon fiber composites. Three hybrid and two non-hybrid weft-knitted reinforced composites employing carbon and aramid bundles were prepared. Low-velocity impact tests at different impact energies were performed, and the impacted samples were analyzed for visual and internal damages utilizing a three-dimensional optical microscope, ultrasonic C-scan, and micro-CT to explore the damage mechanisms. The results demonstrate that the knitted stitches and loop configuration affect the peak load, deflection, and damage crack initiation and expansion of the composites. The alternating configurations of carbon and aramid fiber in the in-plane and thickness directions incorporate the advantages of the high strength of carbon fibers and the toughness of aramid, exhibiting good impact mechanical properties and damage tolerance. The tight loop laminated structure had excellent impact resistance, with prominent peak loads and tiny damage volumes, but it encountered internal delamination and loop breakages.

Probing Physicochemical Performances of 3D Printed Carbon Fiber Composites During 8‐Month Exposure to Space Environment

AbstractCarbon fiber reinforced polymers (CFRPs) offer exceptional properties that make them highly relevant in the aerospace industry, such as high thermal conductivity and an outstanding strength‐to‐weight ratio. Advances in additive manufacturing have expanded the aerospace applications of CFRPs, even allowing for in‐space fabrication of complex structures. Understanding the stability of CFRPs in the harsh conditions of low Earth orbit (LEO) is crucial. LEO exposes materials to extreme environmental factors, such as vacuum, radiation, atomic oxygen, and temperature fluctuations, which can accelerate degradation. To investigate the space‐environment effect on material, changes in properties of 3D‐printed CFRPs are compared with CFRPs made through forging and conventional compression molding. Surface analyses examine morphological, chemical, and matrix composition changes, along with an evaluation of mechanical integrity. Remarkably, the naked 3D printed CFRPs withstood 8 months of LEO exposure similar to the compression molded CFRP samples, with changes in chemical properties limited to the sample's outer surface. Further, despite no protective coatings are used, limited surface erosion and no variation in mechanical strength are observed. These results provide relevant information for the development and deployment of novel 3D printed CFRPs materials for a wide spectrum of terrestrial and space applications.

Application of Bamboo Composite for Unmanned Aerial Vehicle Rod Structure

Researchers are exploring the use of natural fibers, such as bamboo fibers, as a replacement for synthetic fibers in composite materials due to environmental concerns and rising costs. Bamboo fibers have several benefits, including low cost, biodegradability, light weight, and good mechanical qualities. This study focused on the mechanical and physical characteristics of bamboo fiber composites for drone structures. Tensile tests were conducted, revealing a relatively low tensile strength ranging from 22026.99 to 5474.92 N/𝑚𝑚3 compared to carbon fibre composites. The tensile strength was influenced by the composition and ratio of bamboo fibre and epoxy. The density of the bamboo fibre composite ranged from 0.9720 to 0.7790 g/c𝑚𝑚3, which is lower than carbon fibre composites. Increasing the bamboo fibre content resulted in a decrease in density.

Modeling the effect of microscale residual stresses on acoustoelasticity for carbon fiber composites

Modeling the effect of microscale residual stresses on acoustoelasticity for carbon fiber composites

Scalable and passive carbon nanotube thin-film sensor for detecting micro-strains and potential impact damage in fiber-reinforced composite materials

Structural health monitoring (SHM) of brittle structures will require versatile sensing instrumentation that can transmitting transient loadings into rapid electrical responses. This research investigated the sensing performance of CNT Buckypaper (CNT-BP) thin-films on stressed fiber-reinforced composites, which are integral materials to various industries of the infrastructure. Three-point bending experiments revealed an extraordinary gauge factor (∼40) and impressive response linearity. Electrical responses were instantaneous; moreover, low force impacts were detectable, the sensors provided clear indications of spatial recognition. Most importantly, the manufacturing methods are scalable and cost effective compared to commercialized strain gauges. This study examined micro-strain measurements (<1%) of carbon fiber composites, in which bending strain of 0.002% could be detected. In addition, damage progressions of glass fiber composites were recorded in response to low-impact energies. Less than 20 J of impact energy was detectable by the sensor, and the severity could be assessed from drastic changes in the sensing behavior.

Self-standing high-performance Si nanoparticle anchored porous carbon fiber composites for Li-ion batteries

Silicon (Si) is a highly promising anode candidate for lithium-ion batteries. However, the huge volume change of Si during the lithiation/delithiation process might cause serious structural damage, thereby restricting its potential application. Herein, a novel self-standing electrode consisting of porous carbon coated Si (Si@p-C) nanoparticles and carbon fibers (Si@p-C/p-CF) is prepared by a facile electrospinning technique. The three-dimensional carbon fiber framework derived from polyacrylonitrile serves as the support for self-standing electrode, which exhibits superior flexibility and satisfactory electrolyte penetration ability. The porous carbon matrix on the surface of Si nanoparticles can effectively buffer the volume expansion of Si during cycling and prevent direct contact between Si and the electrolyte. Attributed to these merits, the obtained (Si@p-C)0.5/p-CF electrode exhibits outstanding cycling stability with a specific capacity of 940 mAh g−1 at 0.2 A g−1 after 400 cycles, delivering great application potential.

Novel cellular coil design for improved temperature uniformity in inductive heating of carbon fibre composites

Electromagnetic induction has great potential for energy efficient manufacturing of polymer composites. Carbon fibre can be directly heated inductively, achieving rapid, localised, and volumetric heating. The main obstacle to wider adaption of induction in composites processing is the non-uniformity of temperature distribution in-plane and through thickness of composite laminates. This study puts forward a new cellular architecture of the coil and examines the feasibility of addressing the problem of field uniformity. The geometrical parameters of the coil were examined in concurrent modelling and experimental work, aiming at reducing the effect of field cancellation in neighbouring cells and maximising both the coil efficiency and the field uniformity. The paper demonstrates good potential of the new coil designed with significantly improved uniformity of temperature field compared to traditional commercially available coils. This result has been further optimised with parametric finite element analysis to reduce the standard deviation in surface temperature by a further 37%.

Elevating mechanical and biotribological properties of carbon fiber composites by constructing graphene-silicon nitride nanowires interlocking interfacial enhancement

Carbon fiber reinforced dual-matrix composites (CHM) including carbon fiber reinforced hydroxyapatite-polymer matrix composites (CHMP) and carbon fiber reinforced hydroxyapatite-pyrolytic carbon matrix composites (CHMC) have great potential application in the field of artificial hip joints, where a combination of high mechanical strength and excellent biotribological property are required. In this work, the graphene-silicon nitride nanowires (Graphene-Si3N4nws) interlocking interfacial enhancement were designed and constructed into CHM for boosting the mechanical and biotribological properties. The graphene and Si3N4nws interact with each other and construct interlocking interfacial enhancement. Benefiting from the Graphene-Si3N4nws synergistic effect and interlocking enhancement mechanism, the mechanical and biotribological properties of CHM were promoted. Compared with CHMP, the shear and compressive strengths of Graphene-Si3N4nws reinforced CHMP were increased by 80.0% and 61.5%, respectively. The friction coefficient and wear rate were reduced by 52.8% and 52.9%, respectively. Compared with CHMC, the shear and compressive strengths of Graphene-Si3N4nws reinforced CHMC were increased by 145.4% and 64.2%. The friction coefficient and wear rate were decreased by 52.3% and 73.6%. Our work provides a promising methodology for preparing Graphene-Si3N4nws reinforced CHM with more reliable mechanical and biotribological properties for use in artificial hip joints.

Investigation on the mechanical genes of “rigidity-flexibility balance” composite materials similar to feather shaft by SR-CT in-situ experiments

Feather shaft is a fiber reinforced lightweight bio-composite materials with good strength and toughness. It provides possibility for the design of carbon fiber composite that combine rigidity and flexibility, and the key to achieve this is to study the corresponding mechanical gene. Here, inspired by the ring array fiber in the feather shaft, a carbon fiber composite was designed. Through experimental investigation, the “ring array” induced shear strain shielding, progressive damage caused by shear strain reversal and “rigidity-flexibility balance” caused by progressive damage was revealed, which will help establish an approach from structure to mechanical properties through strain and damage.

Hybridization Effect on Interlaminar Bond Strength, Flexural Properties, and Hardness of Carbon-Flax Fiber Thermoplastic Bio-Composites.

Hybridizing carbon-fiber-reinforced polymers with natural fibers could be a solution to prevent delamination and improve the out-of-plane properties of laminated composites. Delamination is one of the initial damage modes in composite laminates, attributed to relatively poor interlaminar mechanical properties, e.g., low interlaminar strength and fracture toughness. This study examined the interlaminar bond strength, flexural properties, and hardness of carbon/flax/polyamide hybrid bio-composites using peel adhesion, three-point bending, and macro-hardness tests, respectively. In this regard, interlayer hybrid laminates were produced with a sandwich fiber hybrid mode, using woven carbon fiber plies (C) as the outer layers and woven flax fiber plies (F) as the inner ones (CFFC) in combination with a bio-based thermoplastic polyamide 11 matrix. In addition, non-hybrid carbon and flax fiber composites with the same matrix were produced as reference laminates to investigate the hybridization effects. The results revealed the advantages of hybridization in terms of flexural properties, including a 212% higher modulus and a 265% higher strength compared to pure flax composites and a 34% higher failure strain compared to pure carbon composites. Additionally, the hybrid composites exhibited a positive hybridization effect in terms of peeling strength, demonstrating a 27% improvement compared to the pure carbon composites. These results provide valuable insights into the mechanical performance of woven carbon-flax hybrid bio-composites, suggesting potential applications in the automotive and construction industries.

Lignin Modification for Enhanced Performance of Polymer Composites.

The biopolymer lignin, which is heterogeneous and abundant, is usually present in plant cell walls and gives them rigidity and strength. As a byproduct of the wood, paper, and pulp manufacturing industry, lignin ranks as the second most prevalent biopolymer worldwide, following cellulose. This review paper explores the extraction, modification, and prospective applications of lignin in various industries, including the enhancement of thermosetting and thermoplastic polymers, biomedical applications such as vanillin production, fuel development, carbon fiber composites, and the creation of nanomaterials for food packaging and drug delivery. The structural characteristics of lignin remain undefined due to its origin, separation, and fragmentation processes. This comprehensive overview encompasses state-of-the-art techniques, potential applications, diverse extraction methods, chemical modifications, carbon fiber utilization, and the extraction of vanillin. Moreover, the review focuses on the utilization of lignin-modified polymer blends across multiple manufacturing sectors, providing insights into the advantages and limitations of this innovative approach for the development of environmentally friendly materials.