Carbon Fiber Reinforced Aluminum Alloy Research Articles

Hydrogen trapping and permeability in carbon fiber reinforced aluminum alloys

Carbon fibers and aluminum-based alloys are the most common choice for today's advanced hydrogen storage solutions due to their lightweight. They also combine exceptional mechanical performance and resistance to most chemicals. However, carbon fibers alone are the primary cost driver for hydrogen storage systems and high-strength aluminum alloys suffer from hydrogen embrittlement. Therefore, alternative carbon fiber-reinforced aluminum alloys can be considered to optimize storage tank costs. But, the effect of adding of carbon fibers on hydrogen trapping in an aluminum-based matrix has not yet been understood. To elucidate this, in this study, the interaction between hydrogen and a carbon fiber-reinforced aluminum alloy was investigated by correlating nano/microstructure characterization, hydrogen mapping techniques, and high-pressure hydrogen permeation tests. It is suggested that carbon fiber-reinforced aluminum alloy has three additional hydrogen trap sites compared to the reported traps for the aluminum alloy. The results showed that hydrogen trapping at these traps reduces the hydrogen permeability of composite material compared to a monolithic aluminum alloy.

Experimental and numerical study on the high-velocity hail impact performance of carbon fiber aluminum alloy laminates

The experiment and finite element method (FEM) simulation of high-velocity hail impact on carbon fiber reinforced aluminum alloy laminates (CARALL) were carried out in this paper. CARALL were prepared via an autoclave process after surface anodizing. The properties of the specimens were verified by mechanical properties testing. The light gas gun was employed to conduct the hail impact tests with different impact velocities, impact angles and ply sequences. The surface damage, displacement of the impact center and deformation depth in different test schemes were compared. The FEM model of the high-velocity impact of hail on CARALL was established using ABAQUS/Explicit. The strain-rate dependent model was adopted for hail while the Johnson-Cook damage constitutive model was adopted for the aluminum alloy layer. The 3D Hashin criterion damage model based on fracture energy was applied for the CFRP layer via the VUMAT subroutine. The cohesive element was inserted between the laminates to investigate the interlaminar damage. The accuracy of FEM was verified by comparing with the results obtained by tests. Combined with the energy absorption and internal damage mechanism, the effects of different parameters on the hail impact resistance of CARALL were studied.

A Numerical Study of Blast Resistance of Carbon Fiber Reinforced Aluminum Alloy Laminates

In this study, the dynamic responses under blast loading of carbon fiber reinforced aluminum alloy laminates with different curvature radii, different numbers of layers, and different layer directions of carbon fiber under blast loading were compared numerically. The finite element models were built with ABAQUS/Explicit. To calibrate the numerical models, experiments on curved carbon fiber and curved aluminum alloy were modeled, and the numerical results showed good agreement with the experimental data. The calibrated numerical models were used to simulate the dynamic response of cylindrical panels subject to external explosion loading. The stiffness degradation coefficient was introduced to more accurately simulate the failure mode of the composite structures. The deformation and energy absorption of carbon fiber reinforced aluminum alloy laminates under different structural parameters were obtained. These simulation findings can guide the theoretical study and optimal design of carbon fiber reinforced structures subject to external blast loading.

Strengthening and toughening of carbon fiber reinforced AA2024 by interface self-regulation reaction

To better develop the potential properties of the short carbon fiber reinforced aluminum alloy 2024 composite in high-temperature environments, TiO2 coating was introduced. The composites were fabricated through powder metallurgy and extrusion. The effects on the tensile strength and elongation ratio of composites were investigated by the coating thickness and testing temperature. The yield strength of AA2024 was improved by the short carbon fiber addition at all testing temperatures, and the ultimate tensile strength was strengthened by short carbon fiber with proper coating thickness. Short carbon fiber with 100 nm thickness can improve both tensile strength and elongation ratio of the composites compared with that with uncoated short carbon fiber. The interphase component and fracture surfaces were investigated, and the self-regulating mechanism and fracture mechanism were discussed. The interfacial products are mainly composed of TiO2, MgO, and TiC, resulting in a self-regulation interface, that transforms the fracture mechanism from fiber shear failure to fiber pulled-out.

Correlation of CFRP and AA7075 Aircraft Wing box structure using FEM

Composite materials are becoming more important in the construction of Mechanical structures. The primary objective of this paper is to analyse the Carbon Fibre Reinforced Plastic (CFRP) and Aluminium alloy (AA 7075) aircraft wing box using finite element method. Both results has been correlated. Both CFRP and AA7075 structures modelling and numerical simulations were executed at various loading conditions. The deformed configuration of the CFRP and AA7075 aircraft wing box along with stress plot have been computed using analysis. Based on these studies, the CFRP and AA7075 central wing box, representing a weight saving of up to one and a half tonnes compared to the most advanced aluminium alloys. The results also expose the increasing strength with reduced weight.

Effect of the Aluminum Matrix on Tensile Properties of Carbon Fiber/Al Composites Prepared by Liquid Extrusion Infiltration

Two-dimensional T300 carbon fiber-reinforced aluminum alloy matrix (2D CF/Al) composites were prepared by the liquid extrusion infiltration (LEI) process with the matrices of 6061Al and ZL102 alloys. Scanning electron microscopy (SEM) detected a satisfactory infiltration effect for both composites. The fiber distribution was uniform, and casting microdefects were not revealed. Transmission electron microscopy (TEM) analysis disclosed the matrix-carbon fibers interface reaction, the brittle Al4C3 phase. Al4C3 sizes were found to be about 150 and 400 nm in 2D CF/6061Al and 2D CF/ZL102 composites, respectively, the interface reaction of a ZL102 matrix was more pronounced. As compared to pure cast alloys, the ultimate tensile strength increased by 134.5. SEM analysis of the tensile specimen fracture demonstrated that the fracture of a 2D CF/6061Al composite was reasonable and for a 2D CF/ZL102 composite it was via the brittle mode, these were caused by the interface bonding.

Burn-Through Responses of Aero-Engine Nacelle using Fiber Metal Composites by ISO2685 Propane-Air Burner

The paper presents experimental investigation on the behavior and burn through responses of a flat plate composite of fiber-metal laminates composites of aluminum alloy 2024-T3 with carbon and natural fibers subjected to environmental conditions in fire designated zone of an aircraft engine exposed to fire. The main purpose of this study is to know the different burn through time responses of different forms of aluminum alloy with synthetic and natural fibers. The composites were designed and developed to improve the flame fire resistance in a fire designated zone of an aircraft engine in near future for prolonged burning through time that will at least withstand the fire flame for 15 minutes according to the ISO 2685 standard. The composites are fabricated by hand lay-up method in a mold of 300 mm x 300 mm and compressed by compression machine. Based on the obtained results, some of the composites are indicated to be fireproof while some others are fire resistant. It is shown that the carbon fiber reinforced aluminum alloy laminate with only aluminum at top and bottom (CF+AA) of the composites can resist more flame temperature than the carbon fiber reinforced aluminum alloy laminate with alternate layers of aluminum and carbon fiber (CARALL) with 7.86%, the sandwich of carbon fiber with flax with 18.2% and the sandwich of carbon fiber with kenaf with 23.43%. In conclusion, the study reveals that aluminum alloy 2024-T3 with carbon fiber and some types of natural fibers composites possess good properties of resisting high temperature of fire designated zone of an aircraft engine nacelle.

Effects of binder on microstructure and properties of carbon fiber-reinforced aluminum alloy composites

Effects of binder on microstructure and properties of carbon fiber-reinforced aluminum alloy composites

Ballistic impact velocity response of carbon fibre reinforced aluminium alloy laminates for aero-engine

Aerospace and other industries use fibre metal laminate composites extensively due to their high specific strength, stiffness and fire resistance, in addition to their capability to be tailored into different forms for specific purposes. The behaviours of such composites under impact loading is another factor to be considered due to the impacts that occur in take-off, landing, during maintenance and operations. The aim of the study is to determine the specific perforation energy and impact strength of the fibre metal laminates of different layering pattern of carbon fibre reinforced aluminium alloy and hybrid laminate composites of carbon fibre and natural fibres (kenaf and flax). The composites are fabricated using the hand lay-up method in a mould with high bonding polymer matrix and compressed by a compression machine, cured at room temperature for one day and post cure in an oven for three hours. The impact tests are conducted using a gun tunnel system with a flat cylindrical bullet fired using a helium gas at a distance of 14 inches to the target. Impact and residual velocity of the projectile are recorded by high speed video camera. Specific perforation energy of carbon fibre reinforced aluminium alloy (CF+AA) for both before and after fire test are higher than the specific perforation energy of the other composites considered before and after fire test respectively. CF +AA before fire test is 55.18% greater than after. The same thing applies to impact strength of the composites where CF +AA before the fire test has the highest percentage of 11.7%, 50.0% and 32.98% as respectively compared to carbon fibre reinforced aluminium alloy (CARALL), carbon fibre reinforced flax aluminium alloy (CAFRALL) and carbon fibre reinforced kenaf aluminium alloy (CAKRALL), and likewise for the composites after fire test. The considered composites in this test can be used in the designated fire zone of an aircraft engine to protect external debris from penetrating the engine shield due to higher values of impact strength and specific perforation energy as highlighted by the test results.

Wear Behavior of PAN- and Pitch-Based Carbon Fiber Reinforced Aluminum Alloy Composites under Dry Sliding Condition

Wear Behavior of PAN- and Pitch-Based Carbon Fiber Reinforced Aluminum Alloy Composites under Dry Sliding Condition

Turning Machinability of Short Carbon Fiber Reinforced Aluminum Alloy Composite

Turning Machinability of Short Carbon Fiber Reinforced Aluminum Alloy Composite

ピッチ系炭素繊維強化アルミニウム合金複合材料の諸特性

ピッチ系炭素繊維強化アルミニウム合金複合材料の諸特性

Microstructure and mechanical properties of z-pinned carbon fiber reinforced aluminum alloy composites

Abstract We report that metal z-pin can be used to enhance the interlaminar strength of carbon fiber reinforced aluminum alloy (Cf/Al) composites. The Cf/Al composites incorporated with AISI 321 steel z-pins as interlaminar reinforcement were fabricated by pressure infiltration, resulting in high composite density. The steel pin reacted with the Al alloy matrix and formed a continuous interfacial reaction layer of FeAl3 to provide strong interfacial bonding between the steel pin and Al alloy matrix. Moreover, it has been found that the diameter of the z-pin has a significant influence on the thickness of the interfacial reaction layer. Double-notched interlaminar shear testing showed that the z-pins increased the shear strength of the Cf/Al composite by 70%–230%.

Bending mechanical property and failure mechanisms of woven carbon fiber-reinforced aluminum alloy composite

Copper-coated woven carbon fiber-reinforced aluminum alloy composite was prepared by spark plasma sintering (SPS). Microstructure, three-point bending mechanical property, and the failure mechanisms of the composite were investigated. Microstructure observation shows that the carbon fibers bond compactly with matrix alloy. Compared with the matrix aluminum alloy, the bending strength, ductility, fracture energy, and cracking resistance of the composite are evidently improved. Microstructure analyses reveal that the high specific strength of carbon fibers and transfer of stress from matrix alloy to carbon fibers are responsible for the increase of the composite bending strength. The expanding of cracks is restrained, and cracking resistance of the composite is improved by adding woven carbon fiber. Attributed to the carbon fibers’ debonding, cracks deflection, and multipath propagation mechanisms, the fracture energy of the composite increases.

Effect of Mg on Microstructure and Mechanical Properties of Copper-Coated Short Carbon Fiber Reinforced Al Alloy Matrix Composite

Copper coated short carbon fiber reinforced aluminum alloy matrix composites have been prepared with 0.3-1.5 wt% Mg as alloying addition by stir casting. Effect of Mg on the microstructure and mechanical properties of the composites was investigated. The microstructure was observed by scanning electron microscopy and the results show that adding Mg can make the distribution of carbon fibers uniform in the composites, reduce laminated and agglomerated. Tensile test and hardness test were carried out, the results show that the tensile strength and the hardness of the composite is increased by 13% and 8% when Mg content is 0.9 wt%.

Effect of Mg on Microstructure and Mechanical Properties of Copper-Coated Short Carbon Fiber Reinforced Al Alloy Matrix Composite

Abstract: Copper coated short carbon fiber reinforced aluminum alloy matrix composites have been prepared with 0.3-1.5 wt% Mg as alloying addition by stir casting. Effect of Mg on the microstructure and mechanical properties of the composites was investigated. The microstructure was observed by scanning electron microscopy and the results show that adding Mg can make the distribution of carbon fibers uniform in the composites, reduce laminated and agglomerated. Tensile test and hardness test were carried out, the results show that the tensile strength and the hardness of the composite is increased by 13% and 8% when Mg content is 0.9 wt%.

Interface study of carbon fibre reinforced Al–Cu composites

The application of continuous carbon fibre-reinforced aluminium matrix composites (C f/Al) in aerospace, automobile, and electric power cable industries is of considerable interest because of their high specific strength, specific modulus, and low coefficient of thermal expansion. In this paper, we report the study on the alloy contribution to the interface of a carbon fibre reinforced aluminium alloy matrix composite. The composites were produced using squeeze casting technology. An Al–Cu alloy was used as the matrix material. Detailed investigations revealed that the aluminium alloy melt fill in the gaps between fibres. The important feature is that the solidification microstructure of Al–Cu matrix alloy is altered by the presence of carbon fibre. The surface of carbon fibre acts as the nucleation site of Al 2Cu phase. Al 2Cu phase prefers to form at the interface between carbon fibre and Al–Cu alloys. Ni coated on carbon fibre does not change the feature.

Influence of high temperature holding on tensile strength of pitch-based carbon fiber reinforced Al–Mg alloy composites fabricated by ultrasonic infiltration method

Carbon fiber reinforced aluminum alloy composites (CF/Al composites) are expected to be applied to electric power cable due to superior specific strength and specific modulus. It is reported that CF/Al composites form aluminum carbide (Al4C3) at the interface between carbon fiber and aluminum alloy. However, in operating condition (300°C, 36 years), the growth of Al4C3 and tensile strength of CF/Al composites have not been clarified. In this study, at first, pitch-based CF (XN-60)/Al composites are fabricated with ultrasonic infiltration method and held at 300, 450, 500°C for a given length of time. Secondary, influence of holding temperature on the quantity of Al4C3 was investigated. Thirdly, relationship between the quantity of Al4C3 and tensile strength of CF/Al composites was examined. As holding temperature increased, the quantity of Al4C3 increased and tensile strength decreased. Reaction kinetics calculation indicated that remaining strength versus theoretical strength (ROM) of the CF/Al composites, held at 300°C for 36 years, was 0.81. That is, it should be better for applying the pitch-based CF/Al composites to electric power cable than the PAN-based CF/Al composites.

Influence of high temperature holding on tensile strength of PAN-based carbon fiber reinforced aluminum–magnesium alloy composites fabricated by ultrasonic infiltration method

Carbon fiber reinforced aluminum alloy composites (CF/Al composites) are expected to be applied to electric power cable due to superior specific strength and specific modulus. But it is reported that CF/Al composites form aluminum carbide (Al4C3) at the interface between carbon fiber and aluminum alloy. However, influence of operating temperature, in usual 300°C, on the growth of Al4C3 and tensile strength of CF/Al composites have not been clarified. In this study, at first, PAN-based CF (M40J) /Al composites are fabricated with ultrasonic infiltration method and hold at 300, 450, 500°C for 64 h. Secondary, influence of holding temperature on the quantity of Al4C3 was investigated. Thirdly, relationship between the quantity of Al4C3 and tensile strength of CF/Al composites was examined. As holding temperature increased, the quantity of Al4C3 increased and tensile strength decreased. By examining extracted fiber with SEM, it was found that tensile strength should be decreased because Al4C3 corroded carbon fiber. Kinetics calculation indicated that remaining strength of the CF/Al composites, held at 300°C for 36 years, was nought. As a result, it will be difficult to apply the CF/Al composites to electric power cable.

Processing and properties of copper-coated carbon fibre reinforced aluminium alloy composites

Aluminium alloy matrix composites with carbon fibre reinforcement were prepared by stir casting method. In order to avoid any interfacial reactions in the carbon fibre reinforced composites, the carbon fibres were coated with copper. The fibres were coated by electroless coating method and then characterized. Composites containing different amounts of carbon fibres were prepared by stir casting and then subjected to age-hardening treatment. Fibre distribution was fairly uniform in the composites containing up to 4 wt% carbon fibres. Tensile strength of the composites was found to be increasing up to 4 wt% carbon fibre.