Carbon Fiber Reinforced Polymer Composites Research Articles

Machining holes in CFRP with laser “drilling + boring” hybrid technique

ABSTRACT This paper presents a novel approach for machining carbon fiber reinforced polymer composite (CFRP), wherein a laser “drilling + boring” hybrid technique is employed. The method consists of initial high-energy pulsed laser drilling at high speeds, followed by subsequent low-energy short-pulsed laser trimming of the hole edges. A detailed examination was carried out on machining accuracy, taper angle, surface roughness, the heat affected zone (HAZ), microstructure, and mechanical properties of the CFRP samples machined with this technique. The findings revealed that the circular holes exhibit a machining accuracy of approximately 30 μm, accompanied by a taper angle measuring 0.37°. Moreover, the regions surrounding the holes display a smooth and pristine surface, devoid of burrs, fiber fractures and serrated textures. Notably, compared with laser rotary cutting method, the “drilling + boring” hybrid technique demonstrates enhancements in surface finish, HAZ control, and mechanical property of the machined holes.

Mechanical and dynamic characteristics for the CFRP, GFRP, and hybrid composites exposed to HCl environment

In the current study, the low-velocity impact (LVI) characteristics of carbon fiber-reinforced polymer (CFRP), glass fiber-reinforced polymer (GFRP), and hybrid composites before and after the corrosive environment exposure were investigated. In this regard, CFRP, GFRP, and hybrid composites were subjected to LVI and tensile loadings after being kept in a 10% diluted HCl environment for 1 week and 1 month, and the impacts of the corrosive environment on the composites’ dynamic and mechanical responses were determined by comparing the outcomes of the control and aged specimens. LVI tests for CFRP, GFRP, and hybrid composites were carried out by transferring 25.2 and 11.2 J impact energy to the specimens with two impact velocities of 3 and 2 m/s, respectively, and thus, the effects of impact energy and hybridization were investigated. Moreover, tensile tests were conducted for the control and aged specimens with 2 mm/min crosshead speed, and thus, the effects of fiber material, hybridization, and corrosive environment on the mechanical properties were determined. The study found that CFRP composites had higher stiffness than GFRPs, whereas hybrid composites exhibited dynamic responses between CFRP and GFRP, as expected. On the other hand, it turned out that the composites absorbed most of the impact energy, which was interpreted as being absorbed by the damage of fiber-reinforced composites, which stand out with their brittle characteristics. Furthermore, it was discovered that the damage severity elevated as expected with a longer aging time, which was attributed to the corrosive liquid attacking the fibers, matrix, and fiber/matrix interfaces and reducing strength. It was also observed that, as predicted, the corrosive effects generally resulted in a reduction in tensile responses, including ultimate strain and tensile strength.

Laser-Induced Decomposition and Mechanical Degradation of Carbon Fiber-Reinforced Polymer Subjected to a High-Energy Laser with Continuous Wave Power up to 120 kW

Carbon fiber-reinforced polymer (CFRP), noted for its outstanding properties including high specific strength and superior fatigue resistance, is increasingly employed in aerospace and other demanding applications. This study investigates the interactions between CFRP composites and high-energy lasers (HEL), with continuous wave laser powers reaching up to 120 kW. A novel automated sample exchange system, operated by a robotic arm, minimizes human exposure while enabling a sequence of targeted laser tests. High-speed imaging captures the rapid expansion of a plume consisting of hot gases and dust particles during the experiment. The research significantly advances empirical models by systematically examining the relationship between laser power, perforation times, and ablation rates. It demonstrates scalable predictions for the effects of high-energy laser radiation. A detailed examination of the damaged samples, both visually and via micro-focused computed X-ray tomography, offers insights into heat distribution and ablation dynamics, highlighting the anisotropic thermal properties of CFRP. Compression after impact (CAI) tests further assess the residual strength of the irradiated samples, enhancing the understanding of CFRP’s structural integrity post-irradiation. Collectively, these tests improve the knowledge of the thermal and mechanical behavior of CFRP under extreme irradiation conditions. The findings not only contribute to predictive modeling of CFRP’s response to laser irradiation but enhance the scalability of these models to higher laser powers, providing robust tools for predicting material behavior in high-performance settings.

Baseline-free assisted lamb wave-based damage detection in CFRP composites using graph convolutional networks and Transformer models

Carbon fiber-reinforced polymer (CFRP) composites are widely used in aerospace but are susceptible to damage, threatening structural safety. Thus, developing an effective structural health monitoring system is essential. This study presents CFRP-former, a novel deep learning framework that detects damage in CFRP composites by constructing spatio-temporal representation graphs of Lamb waves (LWs). The CFRP-former comprises three key modules: graph convolutional neural network (GCNN), a multi-layer perceptron (MLP), and a Transformer Encoder. The GCNN models the topological relationships between LW nodes and sensors. The MLP reduces data dimensionality while preserving key information for subsequent analysis. Meanwhile, the Transformer Encoder, employing multi-head attention mechanisms, captures global time-series patterns in the LW signals. Additionally, the CFRP-former framework includes a parallel module that separately predicts both the size and location of damage. Experiments using only four sensors show that CFRP-former achieves high accuracy in detecting and quantifying damage, with robustness confirmed through ablation tests.

Machining-Induced Burr Suppression in Edge Trimming of Carbon Fibre-Reinforced Polymer (CFRP) Composites by Tool Tilting

Several challenges arise during edge trimming of carbon fibre-reinforced polymer (CFRP) composites, such as the formation of machining-induced burrs and delamination. In a recent development, appropriate-quality geometric features in CFRPs can be machined using special cutting tools and optimised machining parameters. However, these suitable technologies quickly become inappropriate due to the accelerated tool wear. Therefore, the main aim of our research was to find a novel solution for maintaining the machined edge quality even if the tool condition changed significantly. We developed a novel mechanical edge-trimming technology inspired by wobble milling, i.e., the composite plate compression is governed by the proper tool tilting. The effectiveness of the novel technology was tested through mechanical machining experiments and compared with that of conventional edge-trimming technology. Furthermore, the influences of the tool tilting angle and the permanent chamfer size on the burr characteristics were also investigated. A one-fluted solid carbide end mill with a helix angle of 0° was applied for the experiments. The machined edges were examined trough stereomicroscopy and scanning electron microscopy. The images were evaluated through digital image processing. Our results show that multi-axis edge-trimming technology produces less extensive machining-induced burrs than conventional edge trimming by an average of 50%. Furthermore, we found that the tool tilting angle has a significant impact on burr size, while permanent chamfer does not influence it. These findings suggest that multi-axis edge trimming offers a strong alternative to conventional methods, especially when using end-of-life cutting tools, and highlight the importance of selecting the optimal tool tilting angle to minimize machining-induced burrs.

Internal shear damage evolution of CFRP laminates ranging from −100 °C to 100 °C using in-situ X-ray computed tomography

Carbon Fiber Reinforced Polymer (CFRP) composites have been widely used in aerospace due to their high specific stiffness, strength, and fatigue properties. However, the ambient temperature significantly influences CFRP's mechanical properties and damage evolution, deriving from the temperature effect on the microstructural behavior and the mesoscopic damage evolution. In this study, the temperature-dependent in-plane shear failure behavior of CFRP composites was investigated. In-situ X-ray Computed tomography (CT) tensile experiments of laminates ([45°/-45°]2s) at RT, −100 °C, and 100 °C were carried out to study the in-plane shear failure mechanisms. The 3D fracture morphology was extracted with internal damage evolution process estimated and quantified. The in-situ 3D deformation fields of critical regions were acquired using the Digital Volume Correlation (DVC) method. The effect of temperature on strain field and the correlation between the high-strain region and the fracture location were analyzed. The results revealed the temperature correlations and failure mechanisms of CFRP's mechanical characteristics and internal damage evolution process. Compared to room temperature (RT), the delamination damage area of the sample increased by 80 % at 100 °C. Meanwhile, the shear modulus of CFRP decreases by 78.4 % from −100 °C to 100 °C, and the fracture strain increases by 95 % from RT to 100 °C. The DVC results indicated a dispersion of high-strain regions at −100 °C, reflecting the brittle damage characteristics, while an extensive ductile deformation region was captured at 100 °C. Fiber-matrix debonding is the dominant failure mode of composites under shear loading, whereas significant matrix cracking was observed at −100 °C and partial fiber pullout occurred at 100 °C.

Highly protective and functional strengthening strategies for 3D printed continuous carbon fiber reinforced polymer composites: manufacturing and properties

Carbon fiber-reinforced polymer (CFRP) composites have gradually emerged as a crucial material in the aerospace industry. However, inadequate impact resistance and thermal stability limit survival in extreme environments. Inspired by the specific functions of multiple layers of tissue, from bird feathers to the musculoskeletal system. We propose low-cost composite strengthening strategies and efficient novel three-dimensional graphene aerogel manufacturing methods. A novel graphene aerogel/carbon fiber reinforced polymer (GAC) composite prepared by in-situ laser-induced graphene (LIG) layers on the surface of 3D-printed CFRP. GAC composites enhance CFRP's impact protection, thermal insulation, and electromagnetic shielding capabilities. For protection, GAC composites reduce low-velocity impact damage by 26.2%. The graphene layer can increase the thermal buffering capacity of the material four times, and the long-term service temperature can be increased by 40% compared to traditional CFRP. For functionality, the composites enable electromagnetic interference (EMI) shielding effectiveness of up to 50.2 dB. Furthermore, it can achieve surface heating above 400 °C and rapid de-icing through electrothermal effects. The simple and efficient processing method of GAC composites and tunable functionalities holds promise for the development of highly protective and intelligent aircraft skins.

Establishing interphase with “rigid-flexible coupling” crosslinking network by supramolecular structure to improve interfacial properties of high modulus carbon fiber reinforced polymer composites

Establishing interphase with “rigid-flexible coupling” crosslinking network by supramolecular structure to improve interfacial properties of high modulus carbon fiber reinforced polymer composites

An ultrasonic Lamb wave-based non-linear exponential RAPID method for delamination detection in composites

Accurate detection of defects, particularly delamination, in carbon-fiber reinforced polymer (CFRP) composites is crucial but challenging. This study proposes a baseline-free Lamb wave damage imaging framework that incorporates an adaptive time-reversal technique, and a nonlinear exponential reconstruction algorithm for probabilistic inspection of defects (NE-RAPID) in composites. The framework combines two image fusion strategies: full-summation and full-multiplication. NE-RAPID enhances the traditional RAPID algorithm by replacing linear weights with faster-decaying exponential weights, which improves the localization of delamination and other defect regions with higher resolution. A nonlinear exponential weight is introduced to address uneven probability distributions caused by the non-uniform density of the sensor network, thereby improving the accuracy and reliability of defect detection, including delamination. Experimental validation on CFRP composite plates demonstrates that NE-RAPID significantly outperforms RAPID. NE-RAPID achieves a maximum detection error of only 5.1 mm across different frequencies, while RAPID shows a much higher error of 34.41 mm. Furthermore, NE-RAPID produces sharper damage images with fewer artifacts, significantly reducing the risk of false positives. These findings indicate that NE-RAPID is a highly promising method for precise and reliable delamination detection in composite materials.

Numerical study of delamination process of the CFRP composite

A quasi-static approach for an interface damage model, incorporating Rayleigh damping for viscoelastic carbon fiber reinforced polymer composites, is introduced. The interface traction-relative displacement behavior is modeled using a thin adhesive layer, similar to cohesive zone models. The problem is solved numerically with a semi-implicit time-stepping method. The cohesive interface model, integrated into the Finite Element Method, was applied to determine the critical force away from the crack tip. Results showed that the numerical delamination under mode I conditions aligned well with experimental data for the cohesive zone formulations studied. The numerical example demonstrates the effectiveness of the proposed model.

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.

Recovery of carbon fiber from carbon fiber reinforced polymer waste via microwave molten-carbonate pyrolysis

In recent years, the increased use of carbon fiber-reinforced polymer (CFRP) composites has led to a significant rise in waste production. To address this issue, a recycling method using microwave molten salt pyrolysis-oxidation has been proposed to efficiently process CFRP and obtain regenerated carbon fibers (RCFs) under the combined effect of microwave and Na2CO3/K2CO3/Li2CO3 composite molten salt. The mechanism of microwave molten salt pyrolysis was examined in conjunction with the pyrolysis products (pyrolysis oil and gas), furthermore, the microwave molten salt pyrolysis process was optimized. The causes of the changes in the mechanical characteristics and wettability of carbon fibers (CFs) were additionally investigated and analyzed. The RCFs recovered from previous composite materials were processed into new composite materials and mechanically tested to assess their reusability. The study found that using microwave pyrolysis at 350°C for 10 min followed by oxidation at 450°C for 20 min resulted in recovered carbon fibers (RCFs) that retained 98.81 % of the tensile strength of the virgin carbon fibers (VCFs). Additionally, the RCFs showed a tensile modulus enhancement of 14.70 %, with the recovery ratio of carbon fibers as high as 98.44 %. Pyrolysis generates combustible gases like hydrogen (H2), carbon monoxide (CO), and alkanes, alongside products primarily composed of phenols and aromatic compounds. The recycling method can quickly recover high-performance carbon fibers and valuable pyrolysis by-products from CFRP waste, making them highly valuable for resource recycling and the sustainable development of carbon fiber materials.