Carbon Fiber Reinforced Polymer Composites Research Articles

Improvement of curing efficiency and heat resistance of CFRP by the growth of SiCNWs on CF

Carbon fiber-reinforced polymer composites are widely used in modern industry. However, poor heat transfer between layers of carbon fiber cloth during the curing process leading to poor curing of the substrate, long curing cycles, and excessive heat accumulation has become an urgent problem to be solved. A common approach is dispersing highly thermally conductive fillers in the polymer matrix to improve the curing efficiency of the composites. Different from adding fillers, we report a novel method of in situ growth of SiC nanowires (SiCNWs) on the surface of carbon fiber (CF) by the chemical vapor deposition (CVD) method and study the effects of CVD deposition time on curing efficiency and thermal stability of the composites. The results indicate that the nano bridge effect of SiCNWs significantly improves the curing efficiency of the composites. Compared with pure CF/epoxy composites, the curing efficiency can be increased by 38.72%. The cross-linking point between SiCNWs and the resin matrix enhances the thermal stability of the composites and increases the heat resistance index ( T HRI) by 8.4°C.

Structure‐function integrated design of electromagnetic interference shielding and mechanical properties of 2D carbon fiber reinforced polymer composites based on absorption loss regulation

Structure‐function integrated design of electromagnetic interference shielding and mechanical properties of <scp>2D</scp> carbon fiber reinforced polymer composites based on absorption loss regulation

Additive manufacturing of continuous carbon fiber reinforced polymer composites using materials extrusion process. Mechanical properties, process parameters, fracture analysis, challenges, and future prospect. A review

Additive manufacturing of continuous carbon fiber reinforced polymer composites using materials extrusion process. Mechanical properties, process parameters, fracture analysis, challenges, and future prospect. A review

Multiscale image-based modeling for failure prediction of sheet molding compound composite under uniaxial tension

Carbon fiber reinforced polymer (CFRP) composites are extensively utilized as primary load-bearing components in various engineering applications due to their superior strength-to-weight ratio and excellent mechanical properties. However, their intricate microstructural interactions within composite present a significant challenge for failure analysis of CFRP. Although finite element (FE) simulations have been proven feasible to conduct the failure analysis, the classical FE models are developed based on homogeneous fiber characteristics, ignoring the influence of internal structures on the damage evolution process. This paper presents a multiscale image-based modeling approach to predict the tensile failure procedure of chopped carbon fiber sheet molding compound (SMC) composite. To accurately reconstruct the representative volume element (RVE) model of the SMC composite, synchrotron micro-X-ray computed tomography (μXCT) was adapted to explore the SMC internal microstructure. Then microscale RVE models with different fiber volume fractions were constructed to predict the corresponding microcosmic mechanical properties, which were used as the inputs for mesoscale RVE models to determine the constitutive parameters of fiber chips having varied fiber volume and orientations. Finally, the YOLOv5_Seg algorithm was employed to extract the geometric feature parameters of the fiber chips for mesoscale RVE modeling and then the failure location and sequence under uniaxial tension were predicted. It is found that the final simulated failure behaviors were consistent with the experimental observations, confirming the feasibility of this approach for understanding the failure mechanisms of CFRP composites. Thus, once the internal microstructure is determined using experimental techniques or predicted by simulating the composite manufacturing process, this approach can also be utilized for design optimization and performance evaluation for CFRP composites.

In-situ experimental characterization and numerical investigation of the crack initiation of SMC composite under uniaxial tension

This paper explored the crack initiation of sheet molding compound (SMC) composite under uniaxial tensile loads by integrating in-situ experimental characterization and subsequent numerical analysis. Firstly, a synchrotron micro-X-ray computed tomography was utilized to character the morphology and evolution of the microstructure and fracture features of the SMC sample with different loading conditions. Meanwhile, the digital volume correlation technology was employed to determine the internal three-dimensional deformation. Then, a numerical analysis was conducted to describe the relationships among the microstructure, deformation distribution, and position of the crack initiation. Finally, a predictive model was developed based on the internal microstructure and the deformation distribution and then utilized to predict the location and sequence of crack initiation. The good agreement between the predicted results with the experimental ones reveals the feasibility of the proposed model in exploring the fracture behaviors of carbon fiber reinforced polymer composites with complex internal microstructure.

Lay-up design and experimental study of the multiple corrugated diaphragms of carbon fiber reinforced polymer composite

Rebound and deformation of stainless steel during processing have brought great difficulties to forming the multiple corrugated diaphragm (MCD), seriously affecting its performance. Carbon fiber reinforced polymer composite (CFRP) provides a new idea for the design and forming methods of MCD due to its excellent performance and designability. This paper uses ABAQUS finite element analysis software to analyze the influence of laying angle and laying angle ratio on the mechanical properties of composite material MCD. Finally, the axial stiffness of the designed CFRP MCD is tested using a flexible coupling stiffness test bench. The findings demonstrate that the design values are consistent with the experimental results within an acceptable margin of error. The investigation validates the feasibility of the proposed laying design method for CFRP multi-waveform membrane discs (MCDs) and establishes a theoretical foundation for their engineering design and practical application.

An in situ prepared fiber-based piezoresistive film for ultrasonic wave detection on nonplanar carbon fiber-reinforced composites

Owing to the flexibility and high-frequency responsiveness, nanocomposite piezoresistive sensors are suitable for Lamb wave detection on composite materials. Various types of nanocomposite films have been developed for this purpose. However, the inelasticity trait of commonly used electrodes for the nanocomposite films impedes their application on the nonplanar surface of composites. Herein, an in situ prepared piezoresistive film based on graphene and polymethyl methacrylate nanocomposite has been proposed for ultrasonic wave detection on nonplanar carbon fiber-reinforced composites. Electrospinning method is employed to fabricate piezoresistive fiber film onto carbon fiber-reinforced polymer (CFRP) composites, and the sensitivity along the thickness direction is utilized via employing the CFRP layer as one electrode. The fabricated sensitive films exhibit the capability to detect up to 150 kHz ultrasonic signals on curved surfaces. With the help of Hilbert energy spectrum, the precise damage localization on CFRP is achieved by the sensitive film array with a relative error of only 1%. This innovation provides a new in situ preparation method for ultrasonic sensitive film on nonplanar-shaped CFRP components for nondestructive evaluation task.

Enhancing interfacial locking of the CF and PBPESK resin by in-situ electrochemical deposition of MOF nanoparticles

The interfacial bonding of carbon fiber reinforced polymer composites plays a critical role in the overall performance of the composites. Poor interfacial bonding leads to catastrophic damage of composites when subjected to external loads. In this study, three-dimensional (3D) NH2-UiO-66 nanoparticles in-situ synthesis on the carbon fiber (CF) surface using an electrochemical method was achieved facilely and efficiently to enhance the interfacial adhesion of CF/PBPESK composites. The influence of incorporating 3D NH2-UiO-66 nanoparticles into the interphase on the interfacial and mechanical properties of carbon fiber reinforced composites was systematically investigated. The NH2-UiO-66 nanoparticles significantly increased the carbon fibers surface energy. The flexural, interlaminar shear and interfacial shear strength of the N–CF–6min/PBPESK composite were improved by 19 %, 31 %, and 93 %, respectively, compared to the D-CF/PBPESK composite. Furthermore, the interfacial failure mechanism of the composites was investigated. This approach offered a simple and efficient strategy for the in-situ synthesis of interfacial phase characterized by robust mechanical locking effects.

Numerical investigation on machining of additively manufactured CFRP composite with different build orientations and layer widths

Additive manufacturing (AM) is now a widely researched manufacturing technology in the past two decades to adopt in industry for its added advantage of customization and adopting complex geometries with comparatively low buy-to-fly ratio. Carbon fiber reinforced polymer (CFRP) composite has found applications in different high-performance industries for its greatest benefit of high strength-to-weight ratio. Additive manufacturing of CFRP composite (AM-CFRP) opens up the possibility of enhancing mechanical strength using different printing orientations and enables producing complex shapes maintaining sustainable manufacturing perspective. However, Limitation of AM parts of having surface irregularities and questionable dimensional accuracies. To use AM-CFRP parts in high precision assembly or industrial applications, post processing machining is often required to meet the customers’ specification of geometrical tolerances and acceptable surface finish. In this study, the influence of AM parameters on machinability of AM-CFRP composite has been evaluated using finite element analysis (FEA) based numerical simulation. The slot milling operation was simulated with a tungsten carbide end milling tool and AM-CFRP workpiece with four different printing directions, i.e., 0°-90°, 45°-135°, 0°-90°-45°-135°, two different layer widths, i.e., 50 µm and 100 µm, and two in-fill patterns, i.e., solid and perforated structures. The machinability of the 3D printed CFRP has been analyzed based on cutting forces, stress at first contact and maximum stress generation, and temperature increases at the interface during slot milling of AM-CFRP under different AM parameters. Evolution of failure mechanisms of AM-CFRPs under various machining conditions, such as, delamination, matrix rupture etc., have been discussed and chip and burr formation mechanisms have been analyzed. Finite Element analysis (FEA) package ABAQUS/Explicit was used to model 3D micro slot milling operation of AM-CFRP workpiece with appropriate damage and constitutive models, such as, damage initiation, progression and cohesion in adjacent passes and layers.

Dynamics of non-Newtonian fluid–fiber interactions and void formation mechanism based on fused filament fabrication

Due to the presence of internal defects such as voids in the composites manufactured by material extrusion additive manufacturing (MEX AM), the mechanical properties of the composites are significantly below the theoretical optimum. Under this circumstance, this paper is intended to investigate the effects of nozzle feeding angles and to analyze the void formation and evolution of multiphase flow, in which systematic computational fluid dynamics numerical simulations are conducted. The volume of fluid model and overset grid method are used to simulate the extrusion deposition process of carbon fiber-reinforced polymer composites, and the Carreau model is used to represent the shear-thinning behavior of molten polymer. The numerical method is validated against previously experimental and numerical simulation data. The numerical results show that the key factor leading to void formation is the vortices caused by fiber oscillation. The intense vortex at the front end of the fibers disrupts the interface between molten polymer and air, creating a beneficial condition for air to enter. Nozzle tilting can effectively reduce the probability of void formation by decreasing the fiber oscillation velocity. The results of the present study provide insights into the development and optimization of printer nozzles to enable the printing of longer fibers with less probability of potential void formation.

Multiscale modelling of CFRP composites exposed to thermo-mechanical loading from fire

Carbon fibre reinforced polymers (CFRP) are prone to structural damage during extreme events such as fire. Typically, modelling the effect of fire on CFRP structures is carried out through mesoscale analysis to predict overall structural performance. In this study, Finite Element (FE) modelling has been conducted to investigate the effects of fire on CFRP specimens at both meso- and micro-scales. The mesoscale analysis informs the microscale analysis to examine the effects of fire on each constituent of the material. A comparison of thermal analysis at the meso- and micro-scales reveals less than a 6% difference in the predicted nodal temperature. For the first time, fire-induced progressive failure analysis has been conducted on the fibres, matrix, and fibre/matrix interface of representative plies within the composite laminates. Fibre breakage, matrix cracking, and interface debonding were accurately captured using representative volume element (RVE) models under thermo-mechanical loading, showing qualitatively excellent agreement with experimental data.

Smart Carbon Fiber-Reinforced Polymer Composites for Damage Sensing and On-Line Structural Health Monitoring Applications.

High electrical conductivity, along with high piezoresistive sensitivity and stretchability, are crucial for designing and developing nanocomposite strain sensors for damage sensing and on-line structural health monitoring of smart carbon fiber-reinforced polymer (CFRP) composites. In this study, the influence of the geometric features and loadings of carbon-based nanomaterials, including reduced graphene oxide (rGO) or carbon nanofibers (CNFs), on the tunable strain-sensing capabilities of epoxy-based nanocomposites was investigated. This work revealed distinct strain-sensing behavior and sensitivities (gauge factor, GF) depending on both factors. The highest GF values were attained with 0.13 wt.% of rGO at various strains. The stability and reproducibility of the most promising self-sensing nanocomposites were also evaluated through ten stretching/relaxing cycles, and a distinct behavior was observed. While the deformation of the conductive network formed by rGO proved to be predominantly elastic and reversible, nanocomposite sensors containing 0.714 wt.% of CNFs showed that new conductive pathways were established between neighboring CNFs. Based on the best results, formulations were selected for the manufacturing of pre-impregnated materials and related smart CFRP composites. Digital image correlation was synchronized with electrical resistance variation to study the strain-sensing capabilities of modified CFRP composites (at 90° orientation). Promising results were achieved through the incorporation of CNFs since they are able to form new conductive pathways and penetrate between micrometer-sized fibers.

Research progress on high-temperature properties of carbon fiber reinforced polymer composites for cables

Carbon fiber reinforced polymer composites (CFRP) cable has advantages of lightweight, high strength, and excellent durability, providing a new materials for cables and bringing out potential breakthrough in spanning capacity of structures. At present, CFRP cable has already been applied in some engineering bridges. The fire resistance performance of CFRP cable is critical for ensuring structure safety when suffering accidental fire disaster, and clarifying mechanical performance deterioration and failure mechanism of CFRP cable at elevated temperature is fundamental for research of its fire resistance. This paper summarizes current research progress on high-temperature properties of CFRP cable from two levels, including epoxy resin matrix and CFRP composites. Firstly, at resin matrix level, mechanical properties of epoxy resin and its degradation at elevated temperatures are reviewed and analysed, and potential ways to improve high-temperature performance of epoxy resin are suggested. Secondly, at CFRP composites level, high-temperature properties test methods and mechanical performance of CFRP composites in longitudinal direction and transverse direction at elevated temperatures are summarized and discussed. In addition, research shortage of high-temperature properties of CFRP cable is summarized, and corresponding further research is recommended.

Forming Epoxy Coatings on Laser-Engraved Surface of Aluminum Alloy to Reinforce the Bonding Joint with a Carbon Fiber Composite

This study designed laser engraving and resin pre-coating (RPC) treatments on an aluminum alloy (AA) surface to construct through-the-thickness “epoxy pins” for improving the bonding strength with carbon fiber reinforced polymer (CFRP). A laser engraving treatment was used to create a pitted structure on the AA surface; higher wettability was acquired and greater vertical spaces were formed to impregnate epoxy resin, resulting in stronger mechanical interlocking. The RPC technique was further used to guide high-viscosity epoxy resin into pits to form the epoxy coatings and to minimize defects between the resin and the substrate. The bonding strength of the specimen treated with both laser engraving with a unit dimension of 0.3 mm and RPC increased up to 227.1% in comparison with that of the base. The failure modes of the hybrid composites changed from the debonding failure of the AA surface to the delamination-dominated failure of the laminated CFRP composites. It was confirmed that laser engraving is a feasible and effective method when combined with RPC for treating AAs to improve the bonding strength of AA-CFRP composites, which provides a reference for preparing high-performance hybrid composites with metals.

Monitoring of damage evolution in carbon fiber reinforced polymer composites by electrical impedance tomography

Electrical impedance tomography (EIT) has been widely investigated as a nondestructive testing method for carbon fiber reinforced polymer (CFRP) composites. However, the performance of EIT method on the damage process monitoring of the composites is lack of investigation. Herein, quasi-static indentation tests were utilized to introduce damage on CFRP laminates. The damage evolution process was monitored by EIT, while the potential of distinguishing the elastic deformation stage from the plastic stage was analyzed with the aid of acoustic emission. It was found that the changes in conductivity first appeared in the non-central region. With the accumulation of damage, the conductivity changes gradually extended to the center region. The reconstructed damage images were in the crossover shape, which was consist with the micro-CT results that showed the fracture of fibers in ±45° direction. This work further promotes the application of EIT in damage process monitoring of CFRP components.

Assessment of ply thickness and aluminum foils interleaving on the impact response of CFRP composites designed for cryogenic pressure vessels

Carbon fiber reinforced polymer (CFRP) proved to be the best choice to produce cryogenic pressure vessels coupling a reduced weight with superior mechanical performance. Despite this, CFRPs are prone to fuel leakage due to interconnected matrix cracks resulting from mechanical and thermal stresses. Two strategies were combined in this work to reduce fuel permeability, i.e., increase of plies number and metallic film interleaving, evaluating the cryogenic impact response of these new configurations. At first, the only ply thickness effect was assessed and the hybrid sandwich-like (SL) configuration with traditional CFRP (RC) skins and a thin-ply (TP) core displayed impact and residual flexural properties close to RC ones. Then, the effect of aluminum foils interleaving was investigated, and the interleaved SL configuration displayed higher residual flexural properties than interleaved RC for all temperatures, e.g., the residual flexural strength was 30.3 % higher at room temperature and 14.6 % higher at −70 °C, respectively.

Earthquake damage mitigation methods for buried pipelines under compressive loads: A case study of the Thames water pipeline

Promoting tensile failure by providing a proper orientation angle between the pipe axis and the fault line is the main seismic design philosophy for buried steel pipelines. However, most of the severe damage and failures experienced by pipelines are mainly due to negative crossing angle and thus compressive loads acting along the pipeline. This paper investigates different earthquake damage mitigation methods such as Carbon Fiber Reinforced Polymer (CFRP) wrapped pipes, Steel Pipes for Fault Crossing (SPF), and corrugated pipes for buried steel pipelines which are mainly subjected to compressive loads. Therefore, the Thames water transmission pipeline, which is a well-known case study, that suffered major and minor damage due to compressive forces in the 1999 Kocaeli earthquake, is considered to simulate and compare the earthquake damage mitigation capabilities of these countermeasures. The numerical studies are performed by using a three-dimensional nonlinear finite element model. The results show that the use of CFRP composites in buried pipelines, regardless of their thickness, wrapping length, or layer orientation, does not have the expected damage reduction effect, but does increase the effective length between major wrinkles or change the type of pipe failure. On the other hand, SPFs and corrugated pipes are more effective in earthquake damage reduction due to their high axial and rotational capabilities.

Measurement of Interlaminar Shear Properties of Pultruded CFRP Composites Based on Modified DNS Specimens

A double-notch shear (DNS) test was modified for a measurement of interlaminar shear properties of pultruded carbon-fibre-reinforced polymer (CFRP) composites under moderate through-thickness compressive stresses, which were applied by torqued bolts. A range of failure criteria were presented to compare with experimental results. An attempt was made to predict the shear stress-strain relationship in the combined stresses with through-thickness compressive and shear stresses. Results indicate that the modified 2DNS specimen makes the shear surface of the specimen more uniform and reduces the peel stress at the notch tip. The 2DNS fixture made it easier to study the influence of composite interlaminar shear strength and shear stress-strain relationship under moderate through-thickness compression. The initial shear stiffness was not affected by moderate through-thickness compressive stresses. Moderate through-thickness compressive stresses on pultruded CFRP materials can increase interlaminar shear strength and ductility. Of all the failure criteria, the Mohr-Coulomb criterion was preferred to predict the enhancement of the shear strength under moderate through-thickness compression. Based on the Mohr-Coulomb criterion and the inverse solution of Ramberg-Osgood model, a unified equation was proposed and can effectively characterise the interlaminar shear stress-strain relationship under moderate through-thickness compression.

Solvent-free preparation of carbon fiber reinforced dynamically cross-linked vanillin-based polyurethane composites with excellent self-healing and closed-loop recycling performance

Disposing of the wastes generated from the carbon fiber reinforced polymer (CFRP) composite materials after service failure has attracted great attention in recent years. CFRP composites prepared with dynamically covalent cross-linking polymers as matrix resins possess excellent self-healing and recyclability performance, providing an efficient solution to overcome this challenge. However, most of the dynamic cross-linking resins are typically made by high-cost petroleum-derived compounds with extensive use of organic solvents and environmentally unfriendly catalysts. Herein, catalyst-free self-healing and recyclable vanillin-based polyurethanes (V-PUs) via dynamic phenol-carbamate bonds were synthesized by a one-step solvent-free method with a biodegradable PCL as soft segment and biobased vanillin derivative as the chain extender. The optimized V-PUs exhibit Young's modulus of 1.92 GPa, stress at break of 64.98 MPa, glass transition temperature of 95 °C, and over 90 % self-healing and reprocessing efficiency. This excellent self-healing and reprocessing performance can be successfully transferred to the CFRP composite materials fabricated with the V-PUs as matrix resins by hand paste-vacuum bag pressing method. The interlayer shear strength (ILSS) of the composite material is 41 MPa, and the healing efficiency determined by ILSS reaches 85.34 %. Closed-loop recovery of the carbon fiber and matrix resin from the CFRP composite is realized through the solvent dissolution approach due to the dynamic character of the phenol-carbamate bonds, which is of great significance for the development of green economy and sustainable society.

Online vibration monitoring using laser vibrometer and acoustic emission techniques in robotic milling CFRP composites

Carbon fiber reinforced polymer (CFRP) material has superior mechanical properties, often utilized in the aerospace industry. However, its prone to surface defects such as burrs and delamination under the influence of machining vibration, thereby compromising component quality. This study evaluated the relevant vibration signal features via signal processing methods, and investigated the effect of machining parameters on machining stability during robotic milling of CFRP composite. Specifically, the study assessed machining status by analyzing milling signals and compared surface quality between vibration and stable machining stages, the former corresponds to a larger Sa on the machined surface, with more pronounced profile fluctuations. Machining vibration manifests distinct characteristics in laser vibrometer signals, exhibiting in time-frequency plots with short-term signal enhancements at multiple frequencies. This phenomenon occurs more frequently during entry and exit stages. The results indicated that feed speed has a limited effect on milling stability within the selected parameter range, and severe machining vibration occurred at lower spindle speed (12,000 rpm) and higher milling depth (2 mm). Corresponding surface defects formation mechanisms were discussed, revealing that the formation of uncut burrs at the top was related to axial milling force, while interlayer debonding cracks stemmed from variations in fiber orientation between adjacent layers.