Composite Manufacturing Research Articles

Investigation of Composite Materials for Significant Damping Response in Automotive Applications

Through the examination of composite components, engineers and manufacturers can enhance their understanding of failure criteria, the initiation of initial failures, and the propagation of damage within laminates. This study delves into the evolution of impact-induced degradation and establishes upper limits on force or Hertz failure thresholds for three distinct composite categories. Impact investigations reveal that the strength of composite materials significantly increases under dynamic impact conditions compared to static ones, underscoring the material's sensitivity to loading rates. Composite materials play a crucial role in achieving effective ballistic protection for armor platforms, given the varying energy levels of the physical loads they must withstand based on their intended applications. Precise design and manufacturing are necessary to provide adequate protection against impacts of different energies: low-energy impacts from tools during maintenance and operations, intermediate-energy impacts from external elements striking the surface, and high-energy impacts from weapons. Fiber-reinforced composite materials find widespread use across the aviation, marine, and terrestrial industries due to their outstanding specific strength, weight reduction benefits, and ease of manufacturing. They are particularly crucial in aerospace and military applications. Polyester resins offer a cost-effective and easily moldable alternative to epoxy resins in many fiberglass applications. This study aims to explore the low-velocity impact characteristics of E-Glass composites, which are more readily available and cost-effective compared to other reinforced composites. The research focuses on evaluating the impact properties of these materials through testing three different samples.

Influence of washing with sodium lauryl sulphate (SLS) surfactant on different properties of ramie fibres

Green composite materials are a means of reducing reliance on synthetic and especially single-use plastics (SUP) and raising public awareness of the need for urgent action to protect the planet. Natural (lignocellulosic) fibres are increasingly utilized as the reinforcement in polymer matrix composites, in search for increased renewability and sustainability. This work concerns the effect of washing ramie (Boehmeria nivea) fibres using sodium lauryl sulphate (SLS) surfactant. The SLS-treated ramie fibres were examined for their morphological, physical, thermal, structural, and mechanical properties by powder X-ray diffraction (XRD), Fourier transform infrared (FTIR) spectroscopy, thermogravimetric analysis (TGA), scanning electron microscopy (SEM), and tensile testing. SLS treated ramie fibres density and crystallinity index values were 1.23 g/cc and 84.5%, respectively, with a very high cellulose content of 81.3%, because hemicellulose and loose particles were dissolved. SEM images depicted the relevant changes, with no significant damage on treated fibre surfaces. With some assistance from the treatment, fibres initiated their degradation only above 250 °C, culminating at 327 °C, which appears suitable for the manufacturing of composites with the most common matrices.

Sol-gel Chemistry Approaches for the Manufacturing of Innovative Functional Composites for the Aerospace Sector

Sol-Gel is a “bottom-up” synthesis method that enables the production of films, nano/microparticles, fibers, gels, and bulk materials, both glassy and crystalline. Sol-Gel chemistry can be a vital tool for solving problems in several industrial applications where nanotechnology is necessary to overcome constraints. Here, various examples involving silicate-based materials are discussed. Silicatic materials with a variety of morphologies and applications, e.g., monodisperse SiO2 particles ranging in size from a few nanometers to a micron, can be synthesized through hydrolysis and polycondensation reactions of silicon alkoxide precursors. Using an environmentally friendly electrospinning process, silica nanoparticles can be incorporated into polyvinylpyrrolidone (PVP) fibers to create novel, fire-resistant sound absorbers. Additionally, by employing hybrid techniques based on Sol-Gel, the flame retardance of nanocomposites made of silica and epoxy resin as well as epoxy-based composites including hemp, even cured with cycloaliphatic hardeners, can be enhanced. The development of novel materials beneficial for aviation applications, such as hydrophobic (potentially self-anti-icing) coatings, is a further proof of the effectiveness of Sol-Gel chemistry.

Flow mechanisms and their influence on the properties of EGaIn-graphene-poly(ethylene) oxide composites during material extrusion-based additive manufacturing

Polymer composites featuring room temperature liquid alloy particles complimenting other conductive fillers enable unique thermal and electrical properties. Direct-ink-writing approach is an intriguing processing path for these material systems, offering high resolution microstructural and property control. This paper investigates the composition-process-property relationships for material extrusion-based additive manufacturing of EGaIn-Graphene-Poly(ethylene) Oxide composites. Particularly, the influence of composite composition, printing nozzle size and flow rate on electrical conductivity is studied through a mechanistic approach. In that, capillary rheometry and flow modeling was performed to describe the contribution of shear flow and wall slip to the ink flow and how they drive the conductivity of printed structures for various composite ink compositions and process parameters. Influence of composition on material property and process driven conductivity were separately analyzed. Results indicate that EGaIn particles hinder material property-driven baseline average conductivity at high graphene loading. Shear flow and wall slip both increase conductivity. Graphene and total active material concentration increase wall slip and decrease shear flow, leading to a net negative effect of total active material concentration on conductivity. These findings will contribute to composite and process design towards additive manufacturing of composites with as-designed properties.

SCALE Advanced biocomposites unveils its BIO|Power™ and COR|Power™ product lines to replace carbon fiber composites

On March 5, 2024, SCALE Advanced Biocomposites, a developer of bio-based composite reinforcements, unveiled its BIO|Power™ and COR|Power™ product lines at JEC World in Paris. The materials are designed to replace or enhance carbon fiber in lightweight composites. SCALE claims that by doubling down on the inherent benefits of natural fibers and bio-based materials, including low density and excellent damping characteristics, it enables composites manufacturers to use the move to sustainable materials to provide new levels of performance, while reducing materials costs.

Comparative life cycle assessment of aluminium and CFRP composites: the case of aerospace manufacturing

As climate change intensifies and existing resources are depleted, the need for sustainable industries becomes more important. The aviation industry is actively addressing environmental concerns by enhancing fuel efficiency and adopting lighter materials, especially carbon fibre composites. Research has proven that the use of carbon fibre composites provides cumulative benefits in reducing fuel consumption over the entire life cycle of an aircraft. However, existing studies are lack of a comprehensive exploration of the diverse impacts associated with composite manufacturing processes and recycling methods. To address this gap, a comparative life cycle assessment analysis covering the materials’ manufacturing, operation, and end-of-life phases is conducted. This analysis includes aluminium alloy and five different carbon fibre composite materials produced with varied constituents and manufacturing methods. Composite manufacturing processes, encompassing carbon fibre production, resin selection, and composite manufacturing methods, are considered. Weight savings based on the mechanical properties of utilised composite type are also taken into account. Results highlight the potential to mitigate the environmental impact of composite materials through strategic choices in constituent types, manufacturing processes, and disposal scenarios. Moreover, break-even distances indicate that aluminium becomes more environmentally detrimental than the analysed composite structures beyond a flight distance of 300,000 km.

High strength and high toughness Csf/SiC composites prepared by laser powder bed fusion/ reactive melt infiltration with the impregnation of boron-and silicone-containing phenolic resin

Laser powder bed fusion (LPBF) has emerged as an effective method for preparing complex structured silicon carbide (SiC) ceramics. However, the SiC components demonstrate low strength and high brittleness, which remain major challenges limiting its application. To overcome this limitation, short carbon fiber reinforced silicon carbide (Csf/SiC) composites are prepared by combining LPBF and phenolic resin binder impregnation (PRBI)-reactive melt infiltration (RMI), in which high char yield boron-and silicone-containing phenolic resin (BSiPF) impregnation is used to adjust the carbon density of green bodies and to reduce the pore size of green bodies. By optimizing the impregnation process, the carbon density can be brought close to the theoretical optimal value of 0.84 g/cm3, and the reduction of the pore size is conducive to the improvement of the reaction rate at the early stage of the reaction, which enhance the SiC phase content of Csf/SiC composites obtained by RMI. Meanwhile, the application of BSiPF results in a protective pyrolytic carbon (PyC) coating on the surface of Csf, which can reduce the erosion of Csf by molten Si during the RMI process, thus improving the fracture toughness of Csf/SiC composites. The final Csf/SiC composites exhibit the enhanced bulk density, bending strength and fracture toughness, reaching 2.90 ± 0.01 g/cm3, 257 ± 20 MPa, 3.52 ± 0.15 MPa m1/2, respectively. This study provides a new strategy for effective impregnation technique for the additive manufacturing (AM) of high strength and high toughness SiC composites.

Application of Life Cycle Assessment to Analysis of Fibre Composite Manufacturing Technologies in Shipyards Industry

Life cycle assessment (LCA) is used to evaluate the environmental load of fibre composite manufacturing technologies in the shipyards industry in a frame of the Fibre4Yards (Horizon 2020) project. This paper is focused on the LCA of fibre-reinforced polymer (FRP) technologies used to produce all elements of the floating unit, i.e., the conventional vacuum infusion technology for the deck panel and adaptive mould process for superstructure panels, ultraviolet (UV) curved pultrusion process for the production of stiffeners, hot stamping technology for brackets, and three-dimensional (3D) printing and automatic tape placement (ATP) for pillars. Environmental impact was assessed based on standard indicators: Global Warming Potential, water consumption, and fossil resource scarcity. The results indicate that the total carbon footprint of analysed FRP technologies is mainly produced by the type of the materials applied rather than by the amount of energy consumed during the process.

Achieving highly accurate cavity thickness measurements in fabric compaction

The compaction of a fabric reinforcement in a Universal Testing Machine (UTM) allows to determine the achievable fiber volume fraction across a wide range of pressures, a valuable information for composite manufacturing. As seen in the first international compressibility benchmark, inaccuracies in the fabric stack thickness measurement, the approach to compliance correction and the non-parallelism between compaction plates resulted in highly inaccurate compression curves. In this paper, the different variability sources affecting indirect thickness methods, based on the machine displacement, and direct methods with laser sensors are presented and its impact on the accuracy is estimated. In conclusion, both thickness measurement methods produced similar results; however, the thickness measured by direct methods experienced more variability due to minor changes in the rig’s displacement or the orientations between plates, combined with other sources of variability such as external interferences or vibrations from the compaction plate which led to variations in measurement precision throughout the tests.

Amidation-Reaction Strategy Constructs Versatile Mixed Matrix Composite Membranes towards Efficient Volatile Organic Compounds Adsorption and CO2 Separation.

Mixed matrix composite membranes (MMCMs) have shown advantages in reducing VOCs and CO2 emissions. Suitable composite layer, substrate, and good compatibility between the filler and the matrix in the composite layer are critical issues in designing MMCMs. This work develops a high-performance UiO-66-NA@PDMS/MCE for VOCs adsorption and CO2 permea-selectivity, based on a simple and facile fabrication of composite layer using amidation-reaction approach on the substrate. The composite layer shows a continuous morphological appearance without interface voids. This outstanding compatibility interaction between UiO-66-NH2 and PDMS is confirmed by molecular simulations. The Si─O functional group and UiO-66-NH2 in the layer leads to improved VOCs adsorption via active sites, skeleton interaction, electrostatic interaction, and van der Waals force. The layer and ─CONH─ also facilitate CO2 transport. The MMCMs show strong four VOCs adsorption and high CO2 permeance of 276.5 GPU with a selectivity of 36.2. The existence of VOCs in UiO-66-NA@PDMS/MCE increases the polarity and fine-tunes the pore size of UiO-66-NH2, improving the affinity towards CO2 and thus promoting the permea-selectivity for CO2, which is further verified by GCMC and EMD methods. This work is expected to offer a facile composite layer manufacturing method for MMCMs with high VOC adsorption and CO2 permea-selectivity.

Biofabrication of biomimetic undulating microtopography at the dermal-epidermal junction and its effects on the growth and differentiation of epidermal cells.

The undulating microtopography located at the junction of the dermis and epidermis of the native skin is called rete ridges (RRs), which plays an important role in enhancing keratinocyte function, improving skin structure and stability, and providing three-dimensional (3D) microenvironment for skin cells. Despite some progress in recent years, most currently designed and manufactured tissue-engineered skin models still cannot replicate the RRs, resulting in a lack of biological signals in the manufactured skin models. In this study, a composite manufacturing method including electrospinning, 3D printing, and functional coating was developed to produce the epidermal models with RRs. Polycaprolactone (PCL) nanofibers were firstly electrospun to mimic the extracellular matrix environment and be responsible for cell attachment. PCL microfibers were then printed onto top of the PCL nanofibers layer by 3D printing to quickly prepare undulating microtopography and finally the entire structures were dip-coated with gelatin hydrogel to form a functional coating layer. The morphology, chemical composition, and structural properties of the fabricated models were studied. The results proved that the multi-process composite fabricated models were suitable for skin tissue engineering. Live and dead staining, cell counting kit-8 (CCK-8) as well as histology (haematoxylin and eosin (HE) methodology) and immunofluorescence (primary and secondary antibodies combination assay) were used to investigate the viability, metabolic activity, and differentiation of skin cells forin vitroculturing.In vitroresults showed that each model had high cell viability, good proliferation, and the expression of differentiation marker. It was worth noting that the sizes of the RRs affected the cell growth status of the epidermal models. In addition, the unique undulation characteristics of the epidermal-dermal junction can be reproduced in the developed epidermal models. Overall, thesein vitrohuman epidermal models can provide valuable reference for skin transplantation, screening and safety evaluation of drugs and cosmetics.

Prediction of transverse permeability in representative volume elements with closely arranged fibers through the application of delaunay-triangulation and electrical-circuit analogy

The distribution of fibers in composite manufacturing significantly affects fiber bundle permeability, a crucial factor for resin impregnation and void formation, which determines final product quality. However, as the industry increasingly seeks composite materials characterized by high fiber volume fractions, the existing numerical analysis methodologies employed for predicting permeability require a considerable computational cost. In this study, the permeability prediction model was developed using a fluid domain simplification technique based on Delaunay triangulation. The inter-fiber flow was approximated using a lubrication model, and continuity was ensured using a circuit analogy. This model can explain stochastic permeability characteristics according to fiber distribution and accurately predicts the permeability regardless of the distance between fibers. Additionally, compared to existing computational fluid dynamics simulations, it achieved an incredible accuracy of 97.74% and reduced computational costs by an average of 1,700 times.

Failure of 3D-printed composite continuous carbon fibre hexagonal frames

This study presents an approach to enhancing and expanding the structural performance of composite materials by tailoring their geometry. We explored the potential of continuous carbon fibre composite additive printing to create complaint frames based on hexagonal cell design with the aim to better understand and control their mechanical performance. Our investigation examines the failure behaviour of these frames under remote tensile loading. By experimenting with various geometries and aspect ratios at the frame sites, we gained insight into different failure loads and modes. To predict these results, we developed a computational model based on multiscale homogenisation and the Hashin damage criterion, which showed a high degree of precision compared to our experimental results. The findings validate the effectiveness of our computational model, but also highlight the practical applications of additive manufacturing of composites. This research aims to contribute to the advancement of structural design and material optimisation by engineering of composite materials for specific applications, emphasising the integration of their intrinsic strength and lightweight properties with material efficiency and compliance achieved through geometric design considerations.

Micro‐mesoscopic analysis of 3D void formation and evolution in CFRP composite using high‐resolution x‐ray microtomography

AbstractVoid defect is prevalent during the composite manufacturing process and may reduce the mechanical properties of composite structures, while limited information about three‐dimensional void distribution and evolution can be found due to the difficulties in void observation. In this work, void defects at different positions were detected and analyzed using x‐ray microtomography (XRM), and the random forest algorithm was implemented for segmenting components of CFRP samples. Results showed a trend of gradual rising porosity in the axial direction, with an increase of ~250% of porosity at the outlet of resin injection compared to the one at the inlet during the composite manufacturing process. The voids mainly featured with microscale between carbon fibers, with less distribution between fiber bundles and resin‐rich zones. Void defects achieved aggregation at the middle position of manufactured laminate, which is probably related to pressure interception. In the axial direction, the proportion of large‐diameter voids gradually increased, and a large volume of connected voids appeared near the outlet. Due to the shear deformation of resin and fiber and the pressure gradient effect, most of the voids showed stripe shape. The spatial orientation of voids was predominantly along the direction of resin flow and fluctuated due to fiber curl.Highlights 3D void characteristics in CFRP were studied using the XRM technique. Void formation and the effects of fibers on void morphology were analyzed. Dynamic void transport mechanisms during CFRP manufacturing were studied. Location and morphology of voids are helpful for CFRP damage modeling. The effective partitioning of CFRP was achieved using a random forest algorithm.

Trans-scale analysis of 3D braided composites with voids based on micro-CT imaging and unsupervised machine learning

Voids are unavoidable during the manufacturing of 3D braided composites. This study proposes an unsupervised machine learning method combined with micro-computed tomography (micro-CT) scanning and a progressive damage analysis to analyze defects in these composites at a trans-scale level. The method enables the creation of real multiscale models and the determination of the porosity in both the intra-yarn (1.52 %) and inter-yarn (5.04 %) planes. Here, the unsupervised machine learning method is introduced in a trans-scale damage analysis to reduce calculation dimensions and to visualize the clustering data. A user-defined material subroutine (UMAT) is also developed to implement the trans-scale damage model. The experimental validation of the simulation results demonstrates the effective trans-scale damage analysis, showing the predominant pull-shear damage in the yarns, which is primarily located at the interfaces both between the yarns and between the yarns and the matrix. Finally, based on the scanned geometric data the degradation in modulus and strength of 3D braided composites with porosity is studied.

Evaluation and prediction of tensile properties of 3D‐printed continuous carbon/Kevlar fiber‐filled composites by coaxial hybrid process

AbstractContinuous hybrid fiber‐reinforced composites (CHFRCs) have excellent mechanical properties, and strong designability, and are widely used in aerospace and other fields. The development of 3D printing technology offers novel directions in the design and manufacture of complicated CHFRC components in aerospace. For this purpose, this study focused on the design and characterization of hybrid continuous fiber‐reinforced composites prepared by 3D printing. The rapid mold‐free integrated manufacturing of hybrid continuous Kevlar/carbon fiber‐reinforced composites was realized by coaxial hybrid 3D printing technology. The regulation and mechanism of tensile properties of 3D‐printed CHFRCs were elucidated. The tensile strengths of 3D‐printed CHFRCs were enhanced by up to 15.3% and 92.4%, respectively, compared to single continuous carbon and Kevlar fiber composites produced by the same process parameter. A new tensile modulus predicting method for 3D‐printed CHFRCs was proposed. It mitigated the influence of complex interfacial characteristics on mechanical property prediction and achieved precise estimation of the tensile modulus of 3D‐printed CHFRCs. This will provide the theoretical support for the application and development of 3D‐printed CHFRCs.Highlights Mouldless rapid manufacturing of coaxial hybrid fiber composites achieved. The tensile strength and modulus of the fiber composites are greatly improved. A new prediction method for the tensile modulus of 3D‐printed composites is proposed.

Characterization of mechanical properties, efficiency, and design considerations for the additive manufacturing of hybrid composites with continuous fibers

The integration of continuous fibers into additively manufactured plastic components greatly enhances their mechanical properties. Nonetheless, a challenge lies in the limited adaptability of these properties to specific loading scenarios. To address this issue, present research aims to exploit the hybridization of additively manufactured composites, combining diverse fiber materials within a single component. Specifically, fabricating continuous fiber-reinforced hybrid composites through material extrusion enables high flexibility in adapting local fiber materials. To further the understanding of the effects of hybrid fiber reinforcement in additively manufactured plastic parts, this study investigates how distinct stacking sequences in hybrid and non-hybrid PA6-based composite components, reinforced with carbon and glass fibers, affect deformation and failure behavior. Mechanical properties are assessed using tensile, flexural, and impact tests, in conjunction with an analysis of cost and weight efficiency. The results unveil a distinct correlation between stacking sequences and the mechanical properties of additively manufactured composites. While the hybrid samples predominantly exhibit slight negative hybrid effects, a positive hybrid effect of 96.4 % is achieved in terms of impact toughness with an optimized stacking sequence. With the exception of impact strength, specimens reinforced solely with carbon fibers frequently demonstrate a remarkable ratio between mechanical properties, weight, and cost, whereas hybrid composites exhibit a balanced compromise across all tested mechanical properties. Building upon the obtained results, three comprehensive design approaches are introduced and applied, demonstrating the new design possibilities arising from the combination of hybrid composites and additive manufacturing. The developed design approaches and material combinations can be used for a wide range of lightweight construction applications.

Diverted from landfill: Manufacture and characterisation of composites from waste plastic packaging and waste glass fibres

This work explores the use of low-value film-based waste mixed plastics (wMP) from packaging and waste glass fibres (wGF) to produce value-added composites. The study involves producing thermoplastic prepregs with wMP and wGF, manufacturing laminates via compression moulding, optimising wGF content, analysing the interface and assessing the performance of the laminates through mechanical testing. The results indicate that adding 12–26 vol% wGF to unreinforced wMP leads to significant improvements in tensile strength (over 300%), tensile modulus (∼570%), flexural modulus (∼7 80%), compressive strength (∼350%), and compressive modulus (over800%) compared to unreinforced wMP. The significance of having 2-D dispersion of short fibres with partial orientation compared to the more conventionally used 3-D dispersion of short fibres is discussed. The research provides valuable scientific insights into the application of mixed waste materials in composites, aiding the creation of a more circular economy for plastic waste and leading to new composite products.

Post-processing technology of the five-axis additive–subtractive composite manufacturing machine tool

Post-processing technology of the five-axis additive–subtractive composite manufacturing machine tool

Antibacterial properties of magnesium oxide nanoparticles and their composites

Many different disciplines are very much interested in the antibacterial qualities of magnesium oxide nanoparticles (nano-MgO) and their composites. The mechanics behind these qualities and their uses will be covered in detail in this exposition. Although nano-particulate magnesium oxide (nano-MgO) has received much interest as an antibacterial agent, its exact antibacterial mechanisms are still not fully understood, requiring more in-depth research in the areas of stability, processability, and safety. There is a discernible trend in the field of antibacterial materials that combines conventional materials with natural elements. As a newly developed ceramic antibacterial agent with distinct antibacterial properties and a wide range of uses, nano-MgO has become a major area of research interest. As a result, this paper summarizes the many approaches to synthesizing nano-MgO powder, analyzes its antibacterial properties, and offers a current assessment of new developments in the field and composite manufacturing methods. Moreover, it carefully points out common problems and suggests directions for future study. It is essential to the search for cutting-edge antibacterial materials because of its many qualities and wide range of potential uses. NanoMgO will play an essential role in determining the direction of antibacterial agents in the future, given the mounting concern over antibiotic resistance and the demand for environmentally friendly substitutes. This study explores the subtleties of nano-MgO and antibacterial activity in the realm of antibacterial materials. While navigating the complexities of a changing world, understanding and harnessing the potential of nano-MgO is vital for promoting healthier and more sustainable living environments.