Composite Manufacturing Research Articles

Electricity use in big area additive manufacturing of fiber-reinforced polymer composites

In recent years, additive manufacturing (AM), especially large-format additive manufacturing (LFAM), has gained momentum in the manufacturing industry. While LFAM offers benefits over conventional manufacturing processes, such as minimizing material waste and providing vast geometric freedom, assessing its sustainability remains challenging due to limited data, particularly on energy consumption. Most existing data pertain to small-scale or desktop AM and are not directly applicable to LFAM. In this study, we conducted real-time measurements of electricity usage for a type of LFAM known as big area additive manufacturing (BAAM), which typically uses fiber-reinforced polymer pellets as feedstock. We collected electricity usage data from fifteen printing jobs over two months in an industrial production setting. These data fill the existing gap and can be reused to enhance the community’s understanding of LFAM electricity usage, support further research, and promote sustainable development in advanced manufacturing technologies.

Feasibility Study of Metal Matrix Composite (In625-WC) Manufacturing by Laser Engineered Net Shaping (LENS®)

The present paper focuses on the technological approach to manufacturing composite in the form of Inconel 625 reinforced with tungsten carbide particles. Twenty-four samples with reinforcement amounts ranging from 30 to 90% (wt.%) and different numbers of deposited layers were manufactured with the use of Laser Engineered Net Shaping (LENS®). The metallurgical quality, microstructure, chemical and phase composition as well as hardness of the produced composites were determined. Digital microscopy, X-ray powder diffraction and SEM-EDS were employed for this purpose. Despite numerous cracks, the fabricated samples exhibited a greater hardness than single-layer coatings of analogous composition also produced by additive techniques. This phenomenon is likely a result of repeated crystallization of the composites in remelted areas. A dual mechanism of material strengthening is observed in the additively manufactured composites, both by the presence of reinforcing particles and precipitates of secondary phases.

Strengthen of metal-polymer direct molding bonding via three-dimensional porous mechanical interlocking

This paper proposes a direct metal–polymer forming–bonding method using three-dimensional (3D) porous mechanical interlocking to achieve high-strength metal–polymer connections. In this method, porous copper is initially sintered onto copper plates, followed by the infusion of molten polymer into the pores, forming a robust copper–polymer bonded structure. Incorporating microneedle arrays into the copper plates further enhances the bond between the porous copper and the polymer. Characterization of the pore morphology and mechanical properties confirmed the formation of large-area 3D micro-interlocking. Tensile tests on samples with varying porosities showed connection strengths exceeding 30 MPa, with a maximum recorded strength of 37 MPa. Finite element analysis supported the high bonding strength and provided insights into failure mechanisms. This cost-effective technique offers superior copper–polymer bonding strengths, and introduces novel concepts for composite heat exchanger design and manufacturing.

Tensile strength study of mensiang (scirpuss grossus) fibre composites with unsaturated polyester resin matrix

The mensiang (scirpuss grossus) is a plant that grows on moist and watery land. Mensiang plants are commonly used by the society to produce mats or bags that have a strong and durable texture. This mensiang plant has fibres that can be used as reinforcement in polymer composites as a substitute for synthetic fibres. In composite manufacturing, one of the important factors in determining strength is the fraction between fibre and matrix. This study was conducted to determine the effect of different volume fractions of composites on the tensile strength of mensiang fibre reinforcement. Extraction of fibre from the stem of the mensiang plant was done manually by combing, so that the fibre was obtained. The fibres were then naturally dried by the sun for 2-3 days. The composite manufacturing process was carried out by using the hand lay-up method. Specimens and tensile testing procedures refer to the ASTM D638 standard. Several specimens were made by varying the fibre and matrix fractions. The test results showed that the 12.5% fibre volume fraction had the highest tensile strength. In this study there was no chemical treatment on the fibres before the lamination process, thus, this can be suggested for future researchers to study on the effect of chemical treatment on mensiang fibres on fibre bonding with the matrix.

Effect of Teak Wood Dust as Filler Material on Mechanical Properties of Abaca-Pineapple-Epoxy Hybrid Composite

ABSTRACT Composite manufacturers and consumers are increasingly turning to natural-based composites for their biocompatibility, cost-effectiveness, and widespread availability. This study investigates the potential of using teak wood dust as an economical filler material, combined with natural fibers, within an epoxy matrix to create a composite. Specifically, it examines how varying concentrations of teak wood dust—3 wt%, 6 wt%, and 9 wt%—affect the mechanical properties such as tensile strength, flexural strength, impact resistance, inter-laminar shear strength (ILSS), and hardness of an abaca-pineapple-epoxy hybrid composite. The composites were fabricated using the hand layup method followed by hot pressing. Among the different configurations, the composite with 6 wt% teak wood dust (SD-6) demonstrated superior performance, with improvements in tensile, flexural, ILSS, and impact strengths ranging from 3% to 35% compared to other variants. Scanning Electron Microscope (SEM) analysis of the fractured surfaces indicated that the inclusion of 6 wt% teak wood dust enhanced fiber-matrix adhesion, leading to improved mechanical properties of the composite.

Effect of shear-thinning rheology on the dynamics and pressure distribution of a single rigid ellipsoidal particle in viscous fluid flow

This paper evaluates the behavior of a single rigid ellipsoidal particle suspended in homogeneous viscous flow with a power-law generalized Newtonian fluid rheology using a custom-built finite element analysis (FEA) simulation. The combined effects of the shear-thinning fluid rheology, the particle aspect ratio, the initial particle orientation, and the shear-extensional rate factor in various homogeneous flow regimes on the particles dynamics and surface pressure evolution are investigated. The shear-thinning fluid behavior was found to modify the particle's trajectory and alter the particle's kinematic response. Moreover, the pressure distribution over the particle's surface is significantly reduced by the shear-thinning fluid rheology. The FEA model is validated by comparing results of the Newtonian case with results obtained from the well-known Jeffery's analytical model. Furthermore, Jeffery's model is extended to define the particle's trajectory in a special class of homogeneous Newtonian flows with combined extension and shear rate components typically found in axisymmetric nozzle flow contractions. The findings provide an improved understanding of key transport phenomenon related to physical processes involving fluid–structure interaction such as that which occurs within the flow field developed during material extrusion–deposition additive manufacturing of fiber-reinforced polymeric composites. These results provide insight into important microstructural formations within the print beads.

Data-driven optimization of additive composite manufacturing using automated fibre placement: A study on process parameters effects and interactions

The influence of process parameters and their interactions on the interlaminar shear strength (ILSS) of additively manufactured CF-PEEK composites was investigated. The composites were made using a hot gas torch (HGT)-based automated fibre placement (AFP) process. Experimental short beam shear (SBS) tests and FEA numerical simulations with bonding models were conducted to generate data. Various process parameter combinations were analyzed using full-factorial statistical assessment. Results show that ILSS increases with decreasing deposition speeds and increasing HGT temperatures, with consolidation forces having a milder effect. A strong interaction effect between parameters was observed, and the effect of HGT temperature on ILSS depends on material deposition speed. The optimum ILSS were at low deposition speeds (76 mm/s) with high HGT temperatures (900 °C or 950 °C), also evident in the fracture surfaces. This database can aid smart production planning in additive manufacturing of composites by optimizing process parameters for maximum interlaminar strength.

Optimization of Resin Infusion Processes in Composite Manufacturing: An Experimental Study on Void Formation

This research aims at determining the effect of the process parameters namely the vacuum pressure, resin viscosity, temperature and flow rate on formation of voids in the composite manufacturing during resin infusion process. Thus, the study executes controlled experiments and quantitatively examines void content under different parameter configurations to determine that certain conditions substantially reduce voids, improving composite quality. The study reveals that selected vacuum pressure of about 100 kPa, resin viscosity of 200-250 cP at higher temperature and carefully regulated flow rates of 10- 15mL/min help to reduce air bubbles to the barest minimum. These findings provide significant advantages to composite producers on aspects of productivity, mechanical properties and material costs. Similarly, the results indicate the following from secondary research and comparative analysis: Further investigation of real-time void monitoring, exploring advanced optimization with machine learning models. This research is relevant for the enhancement of low-cost and efficient manufacturing techniques in industries that incorporate high-performance composites

Propolis Extract: Weaving Antioxidant Power into Polymeric Composites Through Electrospinning.

The manufacture of composites with bioactive compounds represents a promising strategy for developing advanced materials in biomedical, food, and industrial applications. However, challenges such as stability, bioactivity retention, and controlled release hinder their effectiveness. Electrospinning emerges as a viable technique for encapsulating bioactive compounds, offering advantages such as high surface area, porosity, and gradual release, which are critical for maintaining the bioactivity of embedded compounds. Regarding bioactive composition, propolis has been highlighted as a potential source and has great potential as a biopolymer ingredient due to its antioxidant and antimicrobial properties. This study analyzed the composition and antioxidant activity of three commercial propolis extracts to select the most suitable extract for fiber composite production using zein and polyethylene oxide (PEO), both recognized as safe. The characterization of the electrospun fibers, including morphology, thermal properties, and antioxidant release, was conducted through various analytical techniques. The findings highlight the effectiveness of electrospinning for developing composite materials with bioactive compounds, paving the way for innovations in antioxidant technologies across multiple sectors.

On tailoring morphing mechanics of a bistable composite cylindrical shell through elastic fibre prestressing

A bistable composite cylindrical shell is a thin-walled structure that can change shape between two stable configurations under small energy input, showing great potential to be applied to space deployable mechanics. The internal stress level within a cylindrical shell plays a vital role in determining its morphing mechanics, whilst tailoring the internal stress is tricky for traditional composite manufacturing methods. In this paper, we devise a novel biaxial elastic fibre prestressing (EFP) method to systematic design and produce prestrained carbon-based composite cylindrical shells, with tailorable bistability and morphing mechanics, as well as improved load-carrying capabilities. A biaxial fibre stretching rig was devised to apply tensions on both directions of a plain-weave carbon prepreg simultaneously; prestrained cylindrical shell samples were produced with various prestrain levels to fully evaluate the fibre prestraining effects; a finite element model was established and showed good agreement with experimental observations. The fibre prestraining mechanisms were then proposed. It is found that EFP is effective in tailoring the internal strain/stress level within a composite cylindrical shell, which in turn altering the structural morphing mechanics, and able to significantly lower the maximum tensile strain during shape-changing, thus improve the load-carrying capability. These findings are expected to facilitate structural design of the deployable composite structures and flexible mechanical hinges, by allowing further design freedoms in terms of morphing mechanics and load-carrying capability.

Upgrading Mixed Plastic Waste through Industrial Symbiosis: Pseudoductile Regenerated Cellulose Fiber-Reinforced Shredder Residue Composites.

The mechanical performance of mixed plastic waste from shredder residue is hindered by brittleness and catastrophic failure, limiting its potential applications. In this study, the mechanical properties of mixed plastic is enhanced by reinforcement with rayon fibers through a wet powder impregnation process to leverage the fiber's ductility and entanglement. However, mixed plastic remains poorly dispersed in water during the composite manufacturing, resulting in poorly consolidated composite, which further deteriorates the mechanical properties of mixed plastic from 1.5% strain-at-break to 0.7%. To address this issue, the addition of sodium dodecyl sulfate (SDS) surfactant is explored, where the optimal concentration is found beyond the critical micelle concentration at 10 mM. Lowering the surface tension of water and the adsorption of the SDS on the mixed plastic powder surface facilitated homogeneous dispersion of mixed plastic particles, resulting in well-consolidated rayon fiber-reinforced composites. The 30 wt % rayon fiber-reinforced mixed plastic composite prepared with SDS demonstrated a progressive failure behavior, exhibiting a strain-at-break of 8% and a remarkable 350% increase in impact strength compared to unreinforced mixed plastic. This approach provides a platform to overcome the inherent limitations of mixed plastic waste, offering waste-derived plastic alternatives and reducing the need for fossil-derived virgin materials for a wide range of noncritical applications.

System Integration for Advanced Manufacturing of Composites by Microwave Preheated Resin Infusion: An Experimental Study

System Integration for Advanced Manufacturing of Composites by Microwave Preheated Resin Infusion: An Experimental Study

Optimal vacuum port placement in vacuum-assisted composite manufacturing for leakage detection and localization: a hierarchical optimization approach

Optimal vacuum port placement in vacuum-assisted composite manufacturing for leakage detection and localization: a hierarchical optimization approach

Multisource data fusion for defect detection in composite additive manufacturing using explainable deep neural network

Composite additive manufacturing has the potential to replace traditional composite manufacturing for aerospace applications. Additive manufacturing provides greater adaptability to complex designs, reduce material waste, and streamline the production process. However, in comparison to conventional composite manufacturing methods, additive manufacturing is inherently more susceptible to processing anomalies and defects, primarily due to the novelty of the process and the absence of applied pressure. To effectively capitalize on the benefits of additive manufacturing, a quality and reliability assurance system is critical. In this study, we have generated multisource data to analyze the inner layer thermography and surface quality, employing a multi-camera system including thermal and charge-coupled device cameras. This multisource data is utilized in an explainable zero bias deep neural network framework to detect manufacturing defects. This deep learning algorithm introduces a new zero bias layer following the regular dense layer. After being trained on normal (defect-free) samples of each data stream, the trained model is transformed into an anomaly detector by extracting low dimension features from the zero-bias layer. This allowed identification various anomalies without having to train the model on any defective inputs. As a result, the model's accuracy to detect multiple types of anomalies is higher with multisource data compared to models based on single data source. Anomaly detection accuracy was 99.72% when using data from multiple sources, 98.28% when using only CCD images, and 95% when using only thermal camera data.

Non-standard adhesives for wood-based composites: powder adhesives and bicomponent fibers

Powder adhesives and bicomponent fibres are widely used for composite manufacturing; mainly, they are used for glueing fibres during non-woven production. However, in the woodworking industry, they are rarely used. This study aims to investigate the possibility of powder adhesive and bicomponent fibres utilisation for gluing wood. For this purpose, epoxy-polyester powder adhesive and polyester (PES) bicomponent fibres were selected, and one-component moisture-curing polyurethane adhesive was used as a reference. The selected wood species were spruce, beech, oak and wenge. The differences between powder adhesive- and bicomponent fibre-glued wood joints were observed using scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDX). Mechanical properties of glued wood joints were characterised by tensile shear strength and modelled using finite element modelling (FEM). The adhesives were further characterised using Fourier-transform infrared spectroscopy (FTIR) and differential scanning calorimetry (DSC). The wood joints produced by all combinations of selected wood species and adhesives were comprehensively characterised. The highest values of tensile shear strength were reached by powder epoxy-polyester adhesive (14.85 MPa), whereas joints bonded by bicomponent fibres (5.19 MPa) reached lower values than reference samples.

Anomaly detection for composite manufacturing using AI models

Anomaly detection for composite manufacturing using AI models

Interfacial metallization in segregated structured PEEK composite for enhanced thermal conductivity and electromagnetic interference shielding

The increasing integration of electronic devices has created an urgent demand for multi-functional composites with efficient thermal management and electromagnetic interference (EMI) shielding. In this study, a three-dimensional (3D) continuous metal–carbon hybrid thermally/electrically conductive network structure is fabricated by in-situ nickel plating of core–shell structured polyetheretherketone (PEEK) hybrid particles. The hybrid particles realize phonon and electron dual heat-transfer pathways and reduce the interfacial thermal resistance by using metallic Ni nanoparticles to bridge the gap. Furthermore, the interfacial metallization and segregated structure significantly enrich the multiple electromagnetic wave reflection and attenuation mechanisms. The PEEK composites with metallized-segregated structure and filler content of 28.26 vol% exhibit an excellent through-plane thermal conductivity of 6.52 W m−1·K−1 and an efficient EMI shielding of 91 dB, thus demonstrating their significant potential as multi-functional thermal management materials. The heat-transfer and EMI shielding process of the composites can be visualised using the finite element model, which further proves the effectiveness of the segregated structure and metallization. This simple and efficient strategy is expected to facilitate the manufacture of multi-functional thermal management composites with high thermal conductivity and excellent EMI shielding.

The amount of coir composition effect on the flexural and tensile strength of coir composites

This article is the result of research on the effect of soaking coir in sodium hydroxide solution. The objective of this study is to determine the effect of the composition of coir on the flexural and tensile strength of the coir composite as an effect of immersion in a sodium hydroxide (NaOH) solution. The stages of conducting the research are: (1) preparation of materials and tools; (2) treatment of coir and manufacture of composites; (3) tensile and flexural testing. Before being used as a composite reinforcement, coir was soaked in sodium hydroxide solution with a concentration (percent by weight) of 5% and 10% for 3 hours at room temperature 25oC. After that, the coir was washed with distilled water and then dried at room temperature for 18 hours. Next, we dried the coir in an oven at 90oC for 5 hours. After soaking, coir was used as a composite reinforcement with a composition of 10%, 15%, and 20% by weight of coir. The composite was made using the hand lay-up method, while the flexural test specimens were made based on ASTM-D790, and the tensile test was based on ASTM D 638-03. Then the flexural strength test of the coir composite was carried out using the Shimadzu Flexure Tester with a capacity of 5 kN and a compressive speed of 2 mm/minute. It was concluded that the highest flexural and tensile strengths were obtained by immersing coir in a 5% NaOH solution with 20% coir composition, respectively 41.114 MPa and 20.265 MPa.

MECHANICAL PROPERTIES OF GLASS FIBER AND CARBON FIBER REINFORCED COMPOSITES

The significant potential of glass fiber-based composite materials in aerospace and aviation industries, automotive manufacturing, and medical equipment production is emphasized. It is concluded that glass fiber is much cheaper and less brittle compared to materials like carbon fiber or other plastic fibers, as glass fiber exhibits high resistance to tensile and compressive loads. The main stages of the technological process of composite manufacturing are described, and the key requirements for evaluating the mechanical parameters of glass fiber products are listed. An analysis of the scientific literature has established that the high strength of fiberglass ensures the stability of its thermal conductivity characteristics, making it resistant to environmental influences and aging. The thermal conductivity of fiberglass composites depends on several factors, the most important of which are the type of fiber and matrix, fiber volume fraction, fiber characteristics, control of heat flow, interaction between the matrix and fiber, and operating temperature. It is summarized that the mechanical properties of fiberglass structures depend on a number of factors, the most important of which are: the type of fiber and resin, fiber orientation (aligned, randomly oriented, woven, etc.), and the percentage content of each component.

Fabrication of Aluminium Matrix Composite Powder Reinforced with Silicon Dioxide Tailings for Non-Asbestos Brake Pads (NOB)

Tin mining tailings consist of 80-90% sand and the rest mud. The high levels of Silicon Dioxide (SiO2) in these tailings are hard and can be used as an added material in the manufacture of composites. This research aims to study the physical and mechanical properties of metal matrix composites reinforced with SiO2 powder processed by powder metallurgy, as an effort to provide a replacement material for Non-Asbestos (NOB) motorbike brake linings. The impact of hot compaction pressure in the form of two pressing directions, including 4600, 4500 and 4400 Psi, with a pressing hold of 15 minutes and sintering which includes 30, 20 and 10 minutes, at a temperature of 600 ºC was studied for its effect on hardness and density. Mechanical blending was used with a horizontal ball mill in the ratio of 10:1 at a speed of 90 rpm for 4 hours. The test results showed that the greater the hot compaction pressure and the longer the sintering, the higher the hardness and density values. The highest hardness reached 81.7 HB and the highest density of 2.385 g/cm3 occurred at a bidirectional hot compaction pressure of 4600 Psi, with the lowest wear rate of 0.333 mm3/m. This occurs as a result of the increase in hot compaction has an impact on increasing the contact between powder particles resulting from mechanical alloying to be tighter as a result of which the cavity and porosity decrease