Fabrication Of Composite Materials Research Articles

Fabrication and Testing of Hybrid Polymer Composite Material by Using Carbon, Glass, Kevlar Fibers

Composites which made up of fiber reinforcements are universally endorsed option for the automobiles with a lightweight. Due to the unique properties of fiber-reinforced composites, it became a perfect alternative for traditionally used materials. Most of the automobile industries prefer polymer matrix fiber-reinforced composites for the reason that its light weight helps in carbon emission reduction and Additive manufacturing (AM) produces a complex shaped product from its data, layer by layer, with high precision and much less material wastage. As compared to the conventional manufacturing process, there are many positive environmental advantages of additive manufacturing technologies. Most importantly, there is less waste of raw material and the use of new and smart materials. In this work, we first focused on creating the composite material utilizing the Hand Lay-Up method with materials such as Carbon Fiber/Epoxy Composite with Copper Oxide (CuO) Nanoparticles and Banana Glass Fiber. Following that, we readied ASTMD638 specimens for both compressive and tensile testing. We created an ASTMD638 model for the investigation's tensile and compressive tests using Solid Works design program, and we then saved the design model in STL format. This STL format was uploaded into the CURA software for slicing. The slicing model was then saved into G-code format, and it was printed in a fused deposition modeling machine. Lastly, we tested both specimens using a compressive test setup in a Universal Testing Machine model (INSTRON-3369) UTM, and the results showed 3D printed files. Keywords: Glass Fiber, Banana Fiber, Carbon Fiber, Copper Oxide Nano filler, 3D printing Machine,Corbon Fiber Filament.

Banana pseudo-stem and cattle manure for lactic acid production and the application of polylactic acid-cellulose silver nanoparticle-based nanocomposite films in food storage

Lactic acid is used in various industrial processes, including the production of emulsifiers, polymers, cosmetics, and pharmaceuticals. Fermentation of renewable biomass from natural sources has several advantages over costly chemical methods. Thermal and acidic pretreatments were used to improve the availability of sugars in the medium. Bacillus coagulans was isolated from the banana pseudostem; it was cultured with cattle manure-banana pseudostem for the improved production of lactic acid. Lactic acid production was high in the culture medium containing a 1:1 ratio of cow manure and banana pseudostem after 72 h of fermentation. After 24 h, lactic acid production was 19.4 ± 1.2 g/kg substrate, and it increased after 48 h (20.5 ± 0.1 g/kg substrate), and 72 h (26.3 ± 0.1 g/kg substrate). Lactic acid synthesized by B. coagulans was purified and used for the synthesis of polylactic acid. Polylactic acid was used for the fabrication of composite materials with cellulose and silver nanoparticles. The scanning electron microscopy image showed a smooth surface with uniform particle sizes. The fabricated nanoparticles showed antibacterial activity against food spoilage bacteria. The film was used to pack goat meat and chicken meat. The fabricated film reduced the bacterial load in the stored meat and improved food quality.

Enhancing Composite Material Fabrication through Optimization: Employing Fruit Peel or Shell Powder as Reinforcements using Taguchi-GRA-PCA Methodology

Enhancing Composite Material Fabrication through Optimization: Employing Fruit Peel or Shell Powder as Reinforcements using Taguchi-GRA-PCA Methodology

Graphene-loaded recycled PET: Exploring and enhancing electrical conductivity through processing and laser treatments near the electrical percolation threshold

The blend of polyethylene terephthalate (PET), among the most employed polymer, with graphene, among the most adopted conductive carbon materials, may represent a favorable and sustainable approach for the fabrication of value-added conductive composite materials. This work targeted on the fabrication of melt-compounded composites via injection molding process starting from homemade recycled PET (r-PET) and different loadings of graphene nanoplatelets (GnPs) with different lateral sizes (5 and 25 μm, respectively), used as conductive fillers. Thermogravimetric analysis (TGA), differential scanning calorimetry (DSC) and scanning electron microscopy (SEM) investigations of the different r-PET/GnP-based compounds provided information about composition, textural and structural properties of the melt-compounded specimens, which were correlated with their DC electrical properties. Graphene loadings higher than ca. 9.5–10 wt% were found enough to achieve the electrical percolation within the two material types. With higher graphene loadings, electrical conductivity increased, due to the formation of a progressively developed percolation network. Notably, the effects of the different GnP loadings, GnP lateral sizes and crystallinity degree of the polymer on the conductivity of the of the melt-compounded specimens were investigated. Furthermore, the effect on the electrical properties of CO2 laser irradiation at different scribing speeds on r-PET/GnP composites with graphene loading below the percolation threshold, was verified. By altering locally the morphology and structure, the irradiation process impacted the electrical properties. Notably, the resulting low sheet resistance suggests potential applications in low-power electronics. In brief, the approach and methodology adopted in the present work, along with the results, can contribute to the development of future upcycling into more valuable and sustainable conductive materials and devices based on recycled PET with a reduced environmental footprint.

Investigation of Fiber-Matrix Interface Strength via Single-Fiber Pull-Out Test in 3D-Printed Thermoset Composites: A Simplified Methodology.

The emergence of additive manufacturing technologies for fiber-reinforced thermoset composites has greatly bolstered their utilization, particularly within the aerospace industry. However, the ability to precisely measure the interface strength between the fiber and thermoset matrix in additively manufactured composites has been constrained by the cumbersome nature of single-fiber pull-out experiments and the need for costly instrumentation. This study aims to introduce a novel methodology for conducting single-fiber pull-out tests aimed at quantifying interface shear strength in additively manufactured thermoset composites. Our findings substantiate the viability of this approach, showcasing successful fiber embedding within composite test specimens and precise characterization of fiber pull-out strength using a conventional mechanical testing system. The test outcome revealed an average interfacial strength value of 2.4 MPa between carbon fiber and the thermoset epoxy matrix, aligning with similar studies in the existing literature. The outcome of this study offers an affordable and versatile test methodology to revolutionize composite material fabrication for superior mechanical performance.

Polybutylene adipate terephthalate (PBAT) composites for thermally conductive, fire retardant, high dielectric applications using BaTiO3 and MWCNTs as fillers

This study provides a comprehensive investigation of the fabrication of novel composite materials by blending polybutylene adipate terephthalate (PBAT) with barium titanate (BaTiO3) and multiwalled carbon nanotube (MWCNT) fillers. Prior to fabricating the composites, the filler surface treatments were tailored to enhance their compatibility with the PBAT matrix. Adipic acid (AA), a monomer for PBAT, was employed on the surface of the BaTiO3 particles, while butanediol (BD) also a monomer of PBAT was used to modify the surface of the MWCNTs to ensure effective interaction with the PBAT chains during the composite fabrication process. The composite samples were produced by melt-blending at 140 °C, followed by injection molding at the same operating temperature for subsequent analysis. The results revealed remarkable improvements in the dielectric constant, thermal conductivity, fire retardancy, and tensile strength of the 40 wt% BaTiO3 and MWCNT-PBAT blends compared to pure PBAT. The incorporation of BaTiO3 additionally contributed to enhanced fire retardancy, mechanical properties, and dielectric properties, making the composite material more resistant to ignition and flame spread, thus rendering it suitable for applications requiring elevated fire safety. In addition, the inclusion of MWCNT improved thermal conductivity, enabling promising and efficient heat dissipation in various applications.

Experimental Investigation and Analysis of Mechanical Properties of Chopped Strand Mat-E Glass Fiber Polyster Resin & Silica Powder Composites

Composite materials play a vital role in many industrial applications. Researchers are working on fabrication of new composite materials worldwide to enhance the applicability of these materials. In view of this the mechanical performance of the composite material is essential. The objective of the present work is to analyze the effect of Silica powders content on the mechanical behavior of woolen E-glass 350gm-Glass fiber reinforced. Five different types of composites are fabricated using 0%,2%,4%,6%,8%wt of Silica powders with woolen-E glass fiber and polyester resin. The polyester resin, catalyst and accelerator are mixed in 50:1:1weight ratio in polyester matrix Silica. The aim of the project is to investigate the effect of Silica powders with woolen e-glass 350gm for making the composite material stronger and tougher. The investigation is carried out by mixing different weight percentages of the Silica powders with the polyester resin and preparing individual samples. After woolen- eglass preparation, the materials were properly mixed using the hand-lay techniques and different specimens were prepared with different compositions of the Silica powders. After all the samples were prepared, mechanical tests were carried out on the samples to ascertain the changesobserved due to the composition of Silica powders. The obtained results of various samples specimens were compared and graphically charted to characterize the new composites material. Keywords: Chopped Strand Mat (CSM) 450 G M-Glass Fiber; Silica Powder; Polyester Resin;Hand-Lay;Catalyst;Accelerator.

A Mini-Review: Fabrication of Polysaccharide Composite Materials Based on Self-Assembled Chitin Nanofibers.

This mini-review presents the fabrication methods for polysaccharide composite materials that employ self-assembled chitin nanofibers (ChNFs) as functional components. Chitin is one of the most abundant polysaccharides in nature. However, it is mostly not utilized because of its poor feasibility and processability. Self-assembled ChNFs are efficiently obtained by a regenerative bottom-up process from chitin ion gels using an ionic liquid, 1-allyl-3-methylimodazolium bromide. This is accomplished by immersing the gels in methanol. The resulting dispersion is subjected to filtration to isolate the regenerated materials, producing ChNF films with a morphology defined by highly entangled nanofibers. The bundles are disintegrated by electrostatic repulsion among the amino groups on the ChNFs in aqueous acetic acid to produce thinner fibers known as scaled-down ChNFs. The self-assembled and scaled-down ChNFs are combined with other chitin components to fabricate chitin-based composite materials. ChNF-based composite materials are fabricated through combination with other polysaccharides.

Experimental Investigation and Analysis of Mechanical Properties of Chopped Strand Mat-E Glass Fiber Polyster Resin & Graphite Powder Composites

Composite materials play a vital role in many industrial applications. Researchers are working on fabrication of new composite materials worldwide to enhance the applicability of these materials. In view of this the mechanical performance of the composite material is essential. The objective of the present work is to analyze the effect of graphite powders content on the mechanical behavior of woolen E-glass 350gm-Glass fiber reinforced. Five different types of composites are fabricated using 0%,2%,4%,6%,8%wt of graphite powders with woolen-E glass fiber and polyester resin. The polyester resin, catalyst and accelerator are mixed in 50:1:1weight ratio in polyester matrix graphite. The aim of the project is to investigate the effect of graphite powders with woolen e-glass 350gm for making the composite material stronger and tougher. The investigation is carried out by mixing different weight percentages of the graphite powders with the polyester resin and preparing individual samples. After woolen- eglass preparation, the materials were properly mixed using the hand-lay techniques and different specimens were prepared with different compositions of the graphite powders. After all the samples were prepared, mechanical tests were carried out on the samples to ascertain the changesobserved due to the composition of graphite powders. The obtained results of various samples specimens were compared and graphically charted to characterize the new composites material. Keywords: MattE-Glass 350gm; Polyester resin; Graphite powders; Hand- Lay technique ; Catalyst & Accelerator.

Preparation and Characterization of Bismaleimide-Resin-Based Composite Materials.

This study utilized bismaleimide (BMI) resin, reinforced with introduced ether bonds, as a binding matrix, in combination with silicon carbide (SiC), for the fabrication of composite materials. A thorough investigation was conducted to assess the influence of diverse processing parameters on the mechanical properties and high-temperature thermo-oxidative stability of these composites. Experimental results indicate a notable improvement in the mechanical properties of the composites upon the incorporation of ether bonds, in contrast to their unmodified counterparts. The variation in performance among composites with different ratios and molding densities is apparent. Within a certain range, an increase in resin content and molding density is correlated with improved bending strength in the composites. With a resin content of 27.5 vol% and a molding density of 2.31 g/cm3, the composite achieved a maximum flexural strength of 109.52 MPa, representing a 24% increase compared to its pre-modification state. Even after exposure to high-temperature heat treatment, the composites displayed commendable mechanical properties compared to their pre-ether bond modification counterparts, maintaining 74.5% of the strength of the untreated composites at 300 °C. The scanning electron microscopy (SEM) microstructures of composite materials correlate remarkably well with their mechanical properties.

Manufacturing of bioinspired Bouligand structures using ultrasound assisted 3D printing

Materials with bioinspired Bouligand structures provide a new approach to explore isotropic fiber-reinforced composites. However, it is challenging to manufacture composites with various fibers along with a three-dimensional helical structure. In this work, to accomplish the alignment of a three-dimensional (3D) helical structure of fibers in a composite material, an acoustically aligned fiber technology was incorporated with a rotating mechanism in a stereolithography 3D printer. Firstly, the formation process of acoustic standing wave was simulated and the relationship between standing wave parameters and planar line arrays was then established. Secondly, Bouligand composites with various parameters were fabricated using an acoustic-assisted 3D printing technology and the effect of the angle between the interlayer fiber arrays on the mechanical properties was experimentally measured. Finally, heat sink and meniscus structures with Bouligand structure were fabricated using carbon nanofiber and glass nanofiber, respectively. The 3D printing processing method integrating acoustic alignment technology and rotating mechanism provides a new method for fabrication of composite materials with complex fiber structures.

Application of Yttria Stabilized Zirconia (8YSZ) and NiO Precursors for Fabrication of Composite Material for Anode-Supported SOFCs

Application of Yttria Stabilized Zirconia (8YSZ) and NiO Precursors for Fabrication of Composite Material for Anode-Supported SOFCs

Simultaneous optimization of mechanical and biotribological properties of carbon fibers reinforced hydroxyapatite-polymer composites by constructing networked Si3N4 nanowires

Carbon fibers reinforced hydroxyapatite-polymer composites (CHP) has greatly promising applications in the field of artificial joint replacement, where the integration of splendid biotribological properties and mechanical strength are demanded. Herein, silicon nitride nanowires (SN) with networked structure are introduced to CHP and used as reinforcement materials to form SN reinforced CHP (SN–CHP). The results show that SN with networked structure can provide more deposition sites for hydroxyapatite (HA), increase the cohesion of polymer matrix and strengthen the fiber/polymer interface bonding. With the introduction of SN, mechanical and biotribological properties of SN-CHP exhibit obvious promotion. The shear and compressive strengths of SN-CHP are increased by 28.1 % ± 8.7 % and 28.4 ± 3.8 % compared with CHP, respectively. Furthermore, the friction coefficient and wear rate are reduced by 23.9 % ± 4.3 % and 28.9 % ± 3.8 %, respectively. This work offers a perspective for the fabrication of composite materials with superior cohesion and interface bonding, showing promising applications in artificial joint.

Fabrication of Composite Material by Directly Printing Resin on Aluminum Foam by 3D Printer.

Aluminum foam has relatively low tensile and flexural strengths because it is composed of many pores with thin cell walls. One method of strengthening aluminum foam is to fabricate a composite material with a dense lightweight resin. In this study, the fabrication of composite materials by directly printing resin on an aluminum foam surface using a 3D printer was attempted. The resin was directly printed on both heated and unheated aluminum foam. It was shown that composite materials consisting of aluminum foam and resin can be fabricated by directly printing resin with a 3D printer on both heated and unheated aluminum foam. The resin was softened during the printing process in the case of directly printed resin on heated aluminum foam, allowing more resin to penetrate into the pores than in the case of directly printed resin on unheated aluminum foam. In addition, it was shown that resin can be directly printed on the aluminum foam with a high bonding strength, as a large amount of resin penetrated into the pores, resulting in an anchor effect. That is, composite materials consisting of aluminum foam and arbitrary-shaped resin with relatively high bonding strength can be fabricated when a large amount of resin is allowed to penetrate into the pore.

Recent advances in fabrication of dECM-based composite materials for skin tissue engineering.

Chronic wound management is an intractable medical and social problem, affecting the health of millions worldwide. Decellularized extracellular matrix (dECM)-based materials possess remarkable biological properties for tissue regeneration, which have been used as commercial products for skin regeneration in clinics. However, the complex external environment and the longer chronic wound-healing process hinder the application of pure dECM materials. dECM-based composite materials are constructed to promote the healing process of different wounds, showing noteworthy functions, such as anti-microbial activity and suitable degradability. Moreover, fabrication technologies for designing wound dressings with various forms have expanded the application of dECM-based composite materials. This review provides a summary of the recent fabrication technologies for building dECM-based composite materials, highlighting advances in dECM-based molded hydrogels, electrospun fibers, and bio-printed scaffolds in managing wounds. The associated challenges and prospects in the clinical application of dECM-based composite materials for wound healing are finally discussed.

Characterization of novel lamellar porous Ti3SiC2 as shape-stabilized high-temperature phase change materials composites for durable enhancement thermal storage properties

In pursuit of leveraging porous media for high-temperature phase change materials (PCMs) to enhance the overall thermal conductivity and encapsulation performance of PCMs, this study delves into the corrosion behavior of Ti3SiC2 with a lamellar porous structure in different corrosive environments at both high and low temperatures. By manipulating the solid content to modify the porous structure, the investigation probes the corrosion phenomena and anti-corrosion mechanisms across various porous configurations. The results reveal that F ions exert the most extensive structural degradation on Ti3SiC2. Based on these insights, a successful fabrication of a molten salt phase change composite material, Ti3SiC2/KCl-NaCl, boasting a lamellar structure was achieved. With an increase in solid content, the thermal conductivity escalates from 6.13 to 9.27 W/(m∙K), tripling the heat conductivity of pure KCl-NaCl. However, this also leads to a reduction in latent heat from 126.7 J/g to 46.2 J/g. Consequently, the phase change energy storage performance of PCM prepared by sample 2 emerges as exceptionally commendable. Following 200 thermal cycles on the composite PCM, no discernible structural damage was observed, albeit a slight performance decline. Hence, the lamellar Ti3SiC2/KCl-NaCl structure not only boasts favorable phase change energy storage capabilities but also demonstrates an extended service life.

Non-contact sensing for anomaly detection in wind turbine blades: A focus-SVDD with complex-valued auto-encoder approach

The occurrence of manufacturing defects in wind turbine blade (WTB) production can result in significant increases in operation and maintenance costs of WTBs, reduce capacity factors of wind farms, and occasionally lead to severe and disastrous consequences. Therefore, inspection during the manufacturing process is crucial to ensure consistent fabrication of composite materials. Non-contact sensing techniques, such as Frequency Modulated Continuous Wave (FMCW) radar, are becoming increasingly popular as they offer a full view – cross sectional analysis – of these complex structures during assembly and curing. In this paper, we enhance the quality assurance of WTB manufacturing utilising FMCW radar as a non-destructive sensing modality. Additionally, a novel anomaly detection pipeline is developed that offers the following advantages: (1) We use the analytic representation of the Intermediate Frequency signal of the FMCW radar as a feature to disentangle material-specific and round-trip delay information from the received wave. (2) We propose a novel anomaly detection methodology called focus Support Vector Data Description (focus-SVDD). This methodology involves defining the limit boundaries of the dataset after removing healthy data features, thereby focusing on the attributes of anomalies. (3) The proposed method employs a complex-valued autoencoder to remove healthy features and we introduces a new activation function called Exponential Amplitude Decay (EAD). EAD takes advantage of the Rayleigh distribution, which characterises an instantaneous amplitude signal. The effectiveness of the proposed method is demonstrated through its application to collected data, where it shows superior performance compared to other state-of-the-art unsupervised anomaly detection methods. This method is expected to make a significant contribution not only to structural health monitoring but also to the field of deep complex-valued data processing and SVDD application. The code and dataset will be made publicly available. The code and dataset are available here 11https://github.com/FrusqueGaetan/Focus_SVDD_EAD.

Oxide-Halide Perovskite Composites for Simultaneous Recycling of Lead Zirconate Titanate Piezoceramics and Methylammonium Lead Iodide Solar Cells.

Global concerns over energy availability and the environment impose an urgent requirement for sustainable manufacturing, usage, and disposal of electronic components. Piezoelectric and photovoltaic components are being extensively used. They contain the hazardous element, Pb (e.g., in widely used and researched Pb(Zr,Ti)O3 and halide perovskites), but they are not being properly recycled or reused. This work demonstrates the fabrication of upside-down composite sensor materials using crushed ceramic particles recycled from broken piezoceramics, polycrystalline halide perovskite powder collected from waste dye-sensitized solar cells, and crystal particles of a Cd-based perovskite composition, C6H5N(CH3)3CdBr3 xCl3(1- x ). The piezoceramic and halide perovskite particles are used as filler and binder, respectively, to show a proof of concept for the chemical and microstructural compatibility between the oxide and halide perovskite compounds while being recycled simultaneously. Production of the recycled and reusable materials requires only a marginal energy budget while achieving a very high material densification of >92%, as well as a 40% higher piezoelectric voltage coefficient, i.e., better sensing capability, than the pristine piezoceramics. This work thus offers an energy- and environmentally friendly approach to the recycling of hazardous elements as well as giving a second life to waste piezoelectric and photovoltaic components.

Insights into electro-assisted and selective adsorption of U(VI) using hierarchical porous and activated biocarbon from lotus pods/2D-MoS2/polypyrrole composites through capacitive deionization

The current research work involves the fabrication of orderly mesoporous composite materials based on layered molybdenum disulfide, a hierarchical porous biocarbon from Lotus pods electrodeposited with polypyrrole (2D-MoS2/BCL/PPy). The polypyrrole, as a conducting polymer, was electrodeposited in different mole ratios onto Ni foam supported by 2D-MoS2/BCL. The composite materials were analytically characterized by means of FTIR, SEM-EDX, BET, and XRD techniques. The Lotus pod-driven biocarbon exhibited a high surface area. Among different composites, BCL/PPy-3 (electrodeposited with 0.3 M PPy) was found highly efficient in electro-assisted hexavalent uranium recovery via capacitive deionization because of its impressive specific capacitance (Csp) (100.40 F/g) with improved active surface area and admirable total pore volume. These characteristics made BCL/PPy-3 competitive for enhanced hexavalent uranium ion electrosorption. These features were highly conducive to fast electron transfer and better diffusion of hexavalent uranium ions during the CDI process. The exposed S atoms in BCL/PPy-3 showed good coordination and complexing power for hexavalent uranium ions. The BCL/PPy-3 exhibited an inspiring sorption capacity of 417.90 mg/g at pH = 4.5 and applied voltage (−0.9 V), which is better than many other materials used in CDI applications having similar geometry and morphology. During the electrosorption, the composite electrode BCL/PPy-3 offered a small solution resistance (Rs) (0.69 cm2), a minute charge transfer resistance of Rct (1.19 Ω cm2), and a substantial double layer constant phase element (qdl) of (0.0372 S sn/cm2). These features make this composite electrode highly effective for hexavalent uranium ions removal.

Electromagnetic wave absorption properties of porous carbon nanocomposite prepared by explosion method derived from energetic CuFe-MOF

An energetic heteronuclear metal–organic framework (MOF), denoted as {[CuIIFeIII3O(tza)6(H2O)3]·Cl·(NO3)2·4H2O}n (CuFe-MOF), was successfully synthesized and characterized using various techniques, including single-crystal X-ray diffractometry (XRD), powder X-ray diffractometry (PXRD), and scanning/transmission electron microscopy (SEM/TEM). The compound crystallized in the P63m space group, forming an infinite 3D cationic network composed of [Fe3O(tza)6]+ clusters and Cu2+ ions. Subsequently, we transformed CuFe-MOF into porous carbon nanocomposites, C/Cu/Fe3N/Fe4N/Fe3O4/CuFe2O4, using an explosion method. We then investigated the electromagnetic wave (EMW) attenuation properties and mechanisms of the carbon nanocomposite. Notably, the synthesized C/Cu/Fe3N/Fe4N/Fe3O4/CuFe2O4 composite material demonstrated exceptional EMW absorption. At a low frequency of 4.1 GHz with a thickness of 5.0 mm, it achieved a minimum reflection loss (RL) of −47.7 dB. Even at a high frequency of 17.8 GHz and a thickness of 1.5 mm, the minimum RL reached −41.8 dB. Moreover, this material exhibited a wide effective absorption bandwidth (EAB; RL ≤ −10 dB) spanning 14.9 GHz (3.1–18 GHz) for thicknesses between 1.0 and 5.5 mm. These attributes position the carbon composite as a strong candidate for absorption applications within the Ku, X, and C bands, making it suitable for both military and civilian usage. Our mechanistic analysis suggests that the excellent absorption performance of C/Cu/Fe3N/Fe4N/Fe3O4/CuFe2O4 results from a combination of mechanisms, including electrical and magnetic loss. This research introduces an innovative approach for the fabrication of high-performance carbon composite materials via the explosive method, utilizing multinuclear energetic materials.