Technology Of Composite Materials Research Articles

Special Issue on Advanced Metal Cutting Technologies

Cutting technologies are utilized in many industrial sectors, such as automobile, aircraft, and medical-device manufacturing as well as dies and molds. Thus, the requirements for higher geometric accuracy, better surface integrity, and longer component service lifetimes have substantially increased. In addition, maintaining high machining efficiency while simultaneously reducing power consumption and CO2 emissions during machining is important for sustainable development. This special issue features 11 papers on the most recent advances in cutting technologies for metals and composite materials. - Reverse finishing characteristics of drilling surfaces - Machining error simulation for end milling - Visualization of cutting phenomena using a single-crystal diamond tool - Milling of TiB2 particle-reinforced high-modulus steel - Electrodischarge-assisted turning of carbon fiber-reinforced polymers - Suppression of chatter vibration during double-insert turning - Prediction of surface roughness components during turning - Microtome blades for high-precision tissue sectioning - Boiling of coolant near the cutting edge in high-speed machining - Residual stress during drilling of aluminum alloy - Effect of strain hardening on burr control during drilling This issue provides an understanding of recent developments in cutting technologies, aiming to inspire further research in this field. We deeply appreciate the careful work of all the authors and thank the reviewers for their diligent efforts.

The Three-Dimensional Printing of Composites: A Review of the Finite Element/Finite Volume Modelling of the Process

Composite materials represent the evolution of material science and technology, maximizing the properties for high-end industry applications. The fields concerned include aerospace and defense, automotive, or naval industries. Additive manufacturing (AM) technologies are increasingly growing in market shares due to the elimination of shape barriers, a plethora of available materials, and the reduced costs. The AM technologies of composite materials combine the two growing trends in manufacturing, combining the advantages of both, with a specific enhancement being the elimination of the need for mold manufacturing for composites, or even post-curing treatments. The challenge of AM composites is to compete with their conventional counterparts. The aim of the current paper is to present the additive manufacturing process across different spectrums of finite element analyses (FEA). The first outcomes are building definition (support definition) and the optimization of deposition trajectories. In addition, the multi-physics of melting/solidification using computational fluid dynamics (CFD) are performed to predict the fiber orientation and extrusion profiles. The process modelling continues with the displacement/temperature distribution, which influences porosity, warping, and residual stresses that influence characteristics of the component. This leads to the tuning of the technological parameters, thus improving the manufacturing process.

The formation of research in the field of chemical technology of ceramic and composite materials in Komi Scientific Research Center of the Ural Branch of the Russian Academy of Sciences (1980-1990-ies)

The work is devoted to the history of the formation of one of the scientific directions currently developing at the Institute of Chemistry of the Federal Research Center "Komi Scientific Center of the Ural Branch of the Russian Academy of Sciences". The subject of the study is the process of formation and development of research in the field of materials science and chemical technology of ceramic and composite materials in the Laboratory of Chemistry and Solid State Physics of the Department of Chemistry of the Komi Scientific Center of the Ural Branch of the Russian Academy of Sciences in the 1980s and 1990s. The main attention is paid to the study of the prerequisites for the creation, conditions and main stages of the laboratory, the mechanisms of interaction between a research institution and industrial enterprises of the republic, the analysis of the influence of external factors on the choice of subjects and the development of scientific research, the role of the personality of a scientist in the history of science. The methodological basis of the research is the principle of historicism, a problem-chronological approach, according to which the formation of a scientific direction in an academic institution was studied in the context of the history of industrial development of the region. Based on the documents stored in the funds of the Scientific Archive of the Komi Scientific Research Center of the Ural Branch of the Russian Academy of Sciences and published works, the history of the organization and operation of the laboratory of chemistry and solid state physics was reconstructed for the first time. It is established that one of the main factors that determined the process of formation and development of research in the laboratory during this period was the availability in the republic of promising reserves of mineral raw materials suitable for use in obtaining functional ceramic and composite materials; the necessary research base; the development of high-tech industries in the Komi ASSR. Scientists have been working on the creation of physico-chemical bases for the production of high-tech materials with special properties (magnetic, electrophysical, etc.) based on the mineral raw materials of the republic. New materials with special physical and chemical characteristics obtained in the laboratory were introduced into production, which contributed to the development of the region's industry.

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.

PROPERTIES INVESTIGATION OF POLYESTER RESIN COMPOSITE MATERIALS AND PRODUCTS

The use of composite materials in construction is a promising direction due to their potential to reduce costs and improve the operational characteristics of building structures. The results of this study will allow to determine the optimal formulations and manufacturing technologies of polymer composite materials for use in construction. In this paper, a detailed analysis of the composite material based on polyester resin (polymer sand concrete) used for the manufacture of hatch covers for manholes in water supply and sewage systems is carried out. The main components of the considered composition are quartz sand, unsaturated polyester resin, hardening accelerator - cobalt naphthenate solution and hardener - benzoyl peroxide. As part of the study, the improvement of the composite material’s properties is also considered by adjusting the technological modes of formation. Special attention was paid to the analysis of the hardness of the samples after the research, since this parameter determines the resistance of the material to wear. The effect of different ratios of these components on the physical and mechanical properties of the final material was studied. It was experimentally determined how the consumption of polyester and hardener affects the compressive strength, bending strength, impact toughness and hardness of the composite material. To obtain optimal characteristics, the STATISTICA 12 software package was used to specify the values of the factors that lead to maximum compressive and bending strength. The results of the research are presented in the conclusions in the form of quantitative indicators that indicate the optimal composition to achieve high physical and mechanical characteristics. The response surfaces of the variation factors’ influence on the properties of interest are shown. Keywords: composite material, polymer sand concrete, quartz sand, polyester resin, hardening accelerator - cobalt naphthenate solution and hardener - benzoyl peroxide

Theoretical aspects of the genesis of composites: Dependence of properties on the history of formation

AbstractStudies of the last decades have brought the results of modern natural science into technology of composite materials of the widest range. The methods of percolation theory have become constructive tools for studying the structure of composites, for the purposeful creation of materials with desired properties. In this paper, a computer model of the processes of self‐organization of percolation clusters has been created. The model considers such problems with self‐organization, in which the properties of a percolation cluster are also determined by the history of the system's development. To study the structure and properties of such systems, a three‐dimensional continuum percolation problem with interacting elements is solved in the model. Iterative algorithms for the motion and interaction of particles and clusters, leading to the formation of percolation systems, have been developed. Their structure and properties have been studied, a number of standard parameters have been calculated, and the dependence of the structure and properties of clusters on the rate of system generation, degree of self‐organization, and characteristic values of the correlation length has been studied; analytical dependences of a number of parameters of percolation systems are obtained.

The multi-objective optimization of material properties of 3D print onyx/carbon fiber composites via surrogate model

Composite materials play a prominent role in modern engineering. The emergence of composite material technology has brought about a profound impact on almost, if not all industries. The aerospace industry, for instance, benefits greatly from composite materials. With composites, aircraft weight can be reduced while the structural strength is maintained. As with other classes of materials, 3D printing technique allows composite parts of high complexity to be fabricated with great precision. Additionally, with 3D printing, mechanical properties of the resulted part can be accurately customized and controlled by means of varying matrix-reinforcement proportions. As the composite material can be indefinitely customized in 3D printing, it is crucial to evaluate the mechanical properties of the printed specimen. While testing of printed specimens is usually possible, endless production and testing of specimens not only takes time and resources but also leads to extensive experimental waste. In this study, an optimization-based technique is proposed to determine the optimal 3D printing material proportion in order to reduce the need of unwarranted experimental waste and improve the efficiency of composite material selection process. The study aims to investigate the properties of Onyx/Carbon fiber composite material and the optimization of the 3D printing configuration to achieve desirable mechanical properties. The effects of the number of carbon concentric fiber rings and the percentage of infill density of Onyx used in 3D printing were examined. ASTM D3039 tensile tests were performed to obtain mechanical properties of the printed specimen. Considering the values of tensile strength and modulus of elasticity of the printed material, the printing configurations were optimized using a multi-objective non-dominated sorting genetic algorithm II (NSGA-II) with the Kriging model for objective function estimation. From the proposed optimization technique, it has been found that the maximum tensile strength is attained when the number of concentric fiber rings is equal to 3 while the percentage of Onyx infill density falls in the range of 86–90. Contrarily, the modulus of elasticity is maximized when the number of concentric fiber rings is equal to 4 with the percentage of Onyx infill density in the range of 70–75.

Structural optimization of composite corrugated cores with variable stiffness

Outstanding progress in manufacturing technology of fiber-reinforced composite materials, allows designers to go beyond classical design rules. Composites with variable stiffness are an innovative division of composite materials that provide more efficient designs for engineers due to their diverse design parameters. In this study, a straightforward methodology is presented for the design of sandwich panels with corrugated variable stiffness core. Based on the homogenization method, a unit-cell of the sandwich panel is used as a representative volume element for the sandwich panel with corrugated core. Due to multiple design variables, conventional numerical and analytical methods cannot be applied to variable stiffness composites, thus PYTHON/ABAQUS framework is developed to determine the extensional and bending behavior of unit-cells. Details of this framework including PYTHON scripting and ABAQUS finite element solver are given along with their corresponding functions. Furthermore, the elitist genetic algorithm is incorporated into a framework for the optimum design of variable stiffness cores. Two optimization problems, namely composites with variable thickness and variable angle are considered for unit-cells, and associated constraints, boundary conditions, and fitness functions are discussed in detail. In addition to the benefits of the proposed framework, the obtained results reveal notable enhancement in the extensional and bending behavior of unit-cell. Results reveal that corresponding displacements are significantly improved (up to 80%) when using the optimum variable thickness case. For variable angle cases, the improvement of displacements is up to about 28%.

Exact solutions for the symmetric elastoplastic response of functionally graded pressure vessels

With the development of functionally graded (FG) composite material technology, mechanical analyses of FG pressure vessels have attracted attention. Due to the non-uniform stress distributions inside such vessels, irreversible plastic deformation first occurs in some zones of the structure under the action of external loads. It is necessary to perform an elastoplastic analysis of FG structures to determine their load-bearing capacities. In this paper, exact solutions are obtained for the purely elastic, partially plastic, and fully plastic deformation of FG cylindrical and spherical shell pressure vessels under mechanical loads. The material properties (elastic modulus and yield strength) are assumed to vary nonlinearly in the radial direction of the vessel and the Poisson's ratio is assumed to be constant due to Poisson's ratio slight variations in the engineering materials. The novelty of the current work lies in the presentation of complete exact elastoplastic solutions for FG thick cylindrical and spherical shell pressure vessels, taking into account all deformation zones. Tresca's yield criterion is used to formulate four different deformation zones for an ideal plastic material. All of these states of deformation are studied in detail. It is shown that the elastoplastic response of the FG pressure vessels is notably affected by the radial variation of the material properties. With an increase in the FG parameter β, the first yielding position of the FG pressure vessels changes from the inner surface to the outer surface. The conclusions of this work should help with developing designs of FG pressure vessels to prevent yielding under excessive circumferential stresses.

Eco-Design of Polymer Matrix Composite Parts: A Review.

This research presents a series of analyses related to the eco-design of polymer matrix composite parts, addressing various aspects of it. The main objective was to clarify the definition of ecological design, the benefits of its implementation and its importance in all stages of obtaining a product (design, manufacturing, recycling). Global environmental issues are presented, emphasizing the importance of adopting sustainable approaches in product design and manufacturing. Special attention is paid to the analysis of waste recycling technologies for polymer matrix composite materials. The analysis carried out identifies specific ecological design principles applicable to these materials and presents recent trends in the field. Relevant case studies are highlighted, demonstrating the benefits of ecological design in order to obtain sustainable products. Additionally, the conducted research allowed for finding answers to the questions "what", "why", "when" and "how" it is necessary to apply the principles of eco-design in the case of composite materials with a polymer matrix. In general, the research promotes eco-design as an indispensable strategy for sustainable and responsible production, inspiring companies to adopt these principles for the benefit of the environment and their business performance.

Exact solution of magneto-elastoplastic problem of functionally graded cylinder subjected to internal pressure

With the development of composite material technology, the multi-field coupling analysis of functionally graded (FG) structures has attracted extensive attention. For FG cylindrical pressure vessels, due to the non-uniform distribution of stresses filed in the structure, plastic deformation occurs irreversibly under external load, and Lorentz's force under static magnetic field is also one of the key factors affecting the elastoplastic state. Assuming that the elastic modulus of FG cylinder changes as a power function along the thickness and Poisson's ratio is constant, the hollow cylinder under the combined action of applied magnetic field and internal pressure may have four deformation states containing pure elastic deformation, partial plastic deformation yielding from the inner surface, partial plastic deformation yielding from the outer surface, and full plasticity. In this paper, analytical solutions of stress and displacement fields of the FG cylinder under these four different elastoplastic states are given, and the critical load conditions corresponding to the transition between these four different states are proposed. The correctness of the present analytical solution in this paper is verified by comparing it with the existing results of related simplified problems. In addition, the analytical solution of residual stress distribution caused by unloading internal pressure is discussed for self-reinforcing processing. Based on the analytical solution in this paper, the influence of FG parameter, applied magnetic field and internal pressure on the elastoplastic state, plastic zone size, stresses and displacements distribution of FG cylinder is analyzed in detail. This study shows that for this magneto-elastoplastic problem of FG cylinder, plastic deformation may appear from the inner surface or outer surfaces. With the increase of FG parameter, the first yielding position of FG cylinder changes from the inner surface to the outer surface. In addition, the existence of an applied magnetic field reduces the critical internal pressure required for FG cylinders to yield, making the FG hollow cylinder more prone to plastic deformation.

Emerging Trends in Composite and Advanced Composite Materials Technology for Oil and Gas Industry

Composite and advanced composite materials are new age materials offering multiple benefits such as longer durability, lighter weight, high strength, tailor made properties etc. Lessons have been learnt from successful applications of composite and advanced composite materials and the results indicate that operators, designers and contractors are beginning to take a serious interest in their wide applications in Oil and Gas Industry. The most significant advances in the field of composite materials technology has been the use of glass-reinforced plastics (GRP) for pipelines and piping, structural applications for the top side secondary structures of offshore platforms and onshore installations. The introduction of carbon fibers has opened a new vista for composites applications in oil and gas industry particularly in deepwater operations such as drilling risers, production risers, umbilical, moorings etc. Numerous risers, mooring, pipeline, subsea and topside components made of polyester, titanium, glass/epoxy, and glass/carbon/epoxy materials are in the process of qualification for offshore use. These advanced composite material components have potential to extend capabilities of existing platform concept such as Semi submersibles, TLPs, FPSOs and SPARs. This paper presents the properties and advantages offered by composite and advanced composite materials, their current use and future potential applications in oil and gas industry.

COLD UNIAXIAL PRESSING OF COMOSITE MATERIALS BASED ON PTFE WITH FUNCTIONAL ADDITIVES TIC AND TIB2

In the current work a solid-phase technology of composite materials based on polytetrafluoroethylene (PTFE) with functional additives is investigated. The mentioned additives are titanium carbides and diborides was obtained by self-propagating high-temperature synthesis (SHS). The process of pressing bulk density composite powders into compact blanks in a special mold by loading in a constant speed mode has been studied. Rheological strainstress curves were obtained. The time when a progressive increasing of stress inside the sample was determined. The results of these studies were compared with data for samples without additives (pure PTFE), as well as for compositions with basalt fiber. It is shown that at stresses 171-177 MPa it is possible to achieve a density corresponding to the calculated compact density of 2.24-2.25 g/cm3. The dependence of density variation over the volume of compact specimens has been studied, and a comparative analysis of the compressibility moduli G under uniaxial cold pressing has been carried out.

Current Status and Future Prospects of Composite Materials Technology for Beginners

Current Status and Future Prospects of Composite Materials Technology for Beginners

Infrared defect recognition technology for composite materials

This study mainly involves the methods and experiments of using infrared thermal wave imaging detection technology to detect internal defects in aircraft composite materials. The results were discussed and analyzed. In this paper, the feasibility of the experiment was verified by simulation. In simulation, the minimum accuracy of detectable defects is 4 mm radius under the mesh division accuracy with a correlation coefficient of 5. On this basis, an accurate detection method and prototype nondestructive testing system for defects of aircraft composite materials based on infrared imaging detection technology were designed, which can realize the identification and positioning of defects in aircraft composite material structures, including type, size and accurate depth of defects. Finally, the data collected by the infrared detection system was recognized through YOLO neural network. The test result shows the confidence level for water point defect is more than 0.9, while the confidence level for crack defect is about 0.5. This research result will expand the use case of infrared nondestructive testing technology around the world, and the transformation of the results will help to solve the maintenance problems of aircraft in general aviation.

Augmenting the flexural strength of polymer composites for stronger and more durable prosthetic sockets

AbstractThe objective of this study was to develop a novel approach to enhance the flexural strength of polymer composites used in the fabrication of prosthetic sockets. The effects of control factors such as nozzle hole diameter and internal filling pattern on the flexural behavior of three distinct composite materials were examined: poly lactic acid reinforced with carbon fiber (PLA‐CF), polyethylene terephthalate glycol reinforced with carbon fiber (PETG‐CF), and PLA reinforced with multi‐walled carbon nanotubes (PLA‐MWCNTs), fabricated through fused filament fabrication. During study, samples of each composite material were created using 3D printing technology and underwent flexural testing. Fractography was then performed on the samples, and statistical analysis techniques, including Taguchi's method and response surface methodology (RSM) were used to analyze the results. The study found that the flexural behavior of the prosthetic socket materials varied significantly based on the control factors used. Specifically, a nozzle hole diameter of 0.6 mm and a rectilinear internal filling pattern with PLA‐MWCNTs composite material had the highest flexural strength among the three materials tested. Through this study, the authors demonstrated the potential to improve the design and manufacture of prosthetic sockets, which can lead to better functionality and comfort for the user. The low‐cost transtibial prosthetic socket developed in this study using the optimized composite material and 3D printing technology shows promise as an application in the field of prosthetics. This research can pave the way for the development of even stronger and more durable prosthetic sockets in the future.

Current Status and Future Prospects of Composite Materials Technology for Beginners

Current Status and Future Prospects of Composite Materials Technology for Beginners

Strong Structure Formation of Ceramic Composites Based on Coal Mining Overburden Rocks

Currently, the amount of man-made waste worldwide is steadily increasing. It is, therefore, necessary to constantly look for effective ways of utilization and recycling. It is also necessary to reduce the use of non-renewable resources and reduce the impact on the environment. The use of coal industry waste is currently quite insignificant, amounting to some 10% of the total volume. The work aimed to study the properties of raw materials and study the processes of structure formation during the forming, drying, and firing of composite ceramic produced using overburden rock and additives. The work’s relevance lies in the need to solve environmental, economic, and technological problems related to the utilization of coal mining waste. Experiments of the past prove the possibility of using the waste coal industry as additives in the production of building materials. The article presents the results of studies of the chemical, mineralogical, and granulometric composition of overburden rock in coal mining. Peculiarities of structure formation during the forming, drying, and firing of ceramic composites based on optimal fractional compositions from coal-mine overburden were revealed. Organic and chemical additives were used for the correction of technological properties and improvement of the quality of finished composite products. The physical and mechanical indices of the obtained composite ceramic samples were determined, the analysis of which revealed that the use of highly mineralized carbonaceous rocks as solid additives provided a 2–2.5-fold increase in the strength of the product, 5.6% reduction in water absorption, and an increase in the product frost resistance by 20–25 cycles. The aluminum oxychloride influence on the physical and mechanical indices of the obtained composite articles was reflected in a reduction in their water absorption from 8.2 to 7.0%, a 10–12% increase in strength in compression, and an increase in freeze–thaw resistance by 30–35 cycles. Research results proved that the composition and properties of coal-mine overburden rock are close to those of conventional clays. With special technological preparation, they can be used for the production of composite ceramic products. This will significantly reduce the cost of bricks, to make up for the shortage of high-grade clay raw materials and improve the environmental situation. Nevertheless, further research into the use of coal-mine overburdens in the composite ceramic material technology is warranted.

Current Status and Future Prospects of Composite Materials Technology for Beginners

Current Status and Future Prospects of Composite Materials Technology for Beginners

Study on intelligent and visualization method of ultrasonic testing of composite materials based on deep learning

Intelligent ultrasonic testing technology of composite materials can greatly reduce the dependence on people and improve the efficiency of ultrasonic testing. The combination of ultrasonic testing and visual positioning technology can realize strong robust visual interpretation of ultrasonic testing results. In this paper, the DiMP tracking model is improved by using the Wasserstein distance, and the intelligent tracking and positioning of ultrasonic probe is realized. At the same time, an ultrasonic signal classification network based on 1DCNN depth neural network is built to realize the intelligent detection of ultrasonic signals, and an effective data connection mode is designed to make the two networks work together, so that the intelligent interpretation and visual display of internal defects of composite materials can be realized. The experimental results show that the interpretation accuracy of the method proposed in this paper reaches 98.74%, and the Kappa coefficient reaches 0.97. The comparison results with other models show that the improved model in this paper is more excellent, and the AUC and Precision values are increased by 6.4% and 8.32% respectively compared with the benchmark.