Fiber-reinforced Composite Structures Research Articles

Review of Fiber-Reinforced Composite Structures with Multifunctional Capabilities through Smart Textiles

Review of Fiber-Reinforced Composite Structures with Multifunctional Capabilities through Smart Textiles

Aspect ratio-dependent volume resistivity in unidirectional composites: Insights from electrical conduction behavior

The electrical properties of carbon fibers serve as the foundation for the multifunctional applications of carbon fiber-reinforced composite structures. In scenarios that exploit the electrical characteristics of materials, accurate estimation of electrical resistivity stands as a critical factor. This study endeavors to elucidate the electrical conduction behaviors in unidirectional composites with different fiber orientation angles (0°, 15°, 30°, 45°, 60°, 75°, and 90°) and aspect ratios, thereby deriving the volume resistivity within an arbitrary Cartesian coordinate system. Employing thermal infrared imaging technology and finite element analysis, we identified distinctive electrical conduction behaviors associated with aspect ratios in carbon fiber composite plates. Notably, a critical aspect ratio exists wherein the diagonal yarn is the only conductive path between two electrodes. Below this critical threshold, no direct conductive path exists, and current flows through the shortest distance between parallel yarns. Conversely, beyond the critical aspect ratio value, multiple yarns form conductive paths between the two electrodes. Based on the electrical conduction behavior of unidirectional composites under different angles and aspect ratios, the volume resistivity with finite boundaries was derived and examined under an arbitrary Cartesian coordinate basis.

Integration of ceramic matrix systems into coreless filament wound fiber-reinforced composite lightweight structures for lunar resource utilization

Integrating ceramic matrix systems into coreless filament winding (CFW) enables the creation of sustainable, heat- and fire-resistant fiber composite lightweight structures. This study introduces a chemically bonded ceramic matrix system based on metakaolin, tailored for space applications utilizing lunar resources. The system employs acidic activation for processing with basalt/mineral fibers and alkaline activation for carbon fibers composites. Initially, the constituents of the matrix system are outlined, alongside potential synthesis pathways from lunar resources. Various formulations, incorporating different additives, are proposed. Through coupon compression testing, the most performative formulations for each activation type are selected for further investigation. The addition of zirconium silicate resulted in a higher compressive strength without significantly affecting the compressive modulus. The study then proceeds to experimentally characterize the matrix system’s viscosity. Subsequently, the processability of the proposed matrix system with CFW is demonstrated through the fabrication of generic medium-size lattice samples. Finally, these samples undergo destructive structural testing in compression. While emphasizing material development aspects, the investigation concludes that the feasibility of the proposed concept is validated through the successful fabrication and testing of generic CFW samples, affirming its potential use in space-related structural applications.

Advances in Fibre-reinforced Composite and Sandwich Structures

Advances in Fibre-reinforced Composite and Sandwich Structures

Performance and failure modes of continuous fibre-reinforced energy absorption tubes by cylindrical layered 3D printing

ABSTRACT Precisely controlling the distribution of continuous fibres on a cylindrical surface is crucial for manufacturing high-performance continuous fibre-reinforced composite (CFRC) tubular structures. Existing manufacturing processes are complex, hindering the regulation of fibre orientation and content. Therefore, this study achieved unrestricted control of 3D-printed continuous fibres in terms of content and arbitrary orientation on a cylindrical surface using a cylindrical layered path planning strategy. The study investigated the impact of different fibre orientations and printing parameters on the compressive performance and energy absorption of 3D-printed CFRC tubes under quasi-static axial compression by analysing fibre distribution and failure modes. Compared to the flat layered printing strategy, the cylindrical layered printing strategy showed significant increases in compressive strength and energy absorption, by 44.3% and 85.2%, respectively. A cusp height analysis model demonstrated that the cylindrical layered printing strategy significantly enhances forming accuracy compared to the conventional flat layered method. The CFRC lightweight energy absorption tubes fabricated with this strategy demonstrated the viability of the manufacturing process. This new manufacturing technology has significant potential for producing high-performance and high-precision CFRC energy absorption tubes, applicable in aeronautics and astronautics.

Concurrent level set topology and fiber orientation optimization of fiber-reinforced composite structures

Concurrent level set topology and fiber orientation optimization of fiber-reinforced composite structures

Investigation of interfacial shear strength of hybrid fibre-reinforced polyamide composite structures made by fused granular fabrication and automated tape laying

Fused granular fabrication (FGF), a technology within the framework of large format additive manufacturing (LFAM), focuses on cost-effective granulate-based manufacturing, eliminating the need for semi-finished filaments. The anisotropic behaviour of 3D-printed parts is evident in their varying mechanical properties along different axes, which are amplified when fibres are incorporated into the material. In this study, a significant improvement in the flexural stiffness and strength of manufactured FGF structures and a lowering of anisotropic behaviour have been achieved through the integration of continuous fibre-reinforced unidirectional tapes (UD-tapes). With the employment of automated tape laying (ATL), UD-tapes have been applied to plate structures manufactured by the FGF process. The manufactured structures were characterised in terms of their morphology and mechanical behaviour by 3-point-bending tests. As the effectiveness of the UD-tape reinforcement requires sufficient bonding between the UD-tape and the FGF structure, the interface morphology and interface strength were investigated. Different surface preparations were considered prior to tape laying to account for the influence of the surface quality of FGF structures. It was demonstrated that UD-tape laying on an FGF surface that was prepared by a milling process provides a higher interface shear strength compared to an untreated FGF surface.

Novel Response Surface Technique for Composite Structure Localization Using Variable Acoustic Emission Velocity.

The time difference of arrival (TDOA) method has traditionally proven effective for locating acoustic emission (AE) sources and detecting structural defects. Nevertheless, its applicability is constrained when applied to anisotropic materials, particularly in the context of fiber-reinforced composite structures. In response, this paper introduces a novel COmposite LOcalization using Response Surface (COLORS) algorithm based on a two-step approach for precise AE source localization suitable for laminated composite structures. Leveraging a response surface developed from critical parameters, including AE velocity profiles, attenuation rates, distances, and orientations, the proposed method offers precise AE source predictions. The incorporation of updated velocity data into the algorithm yields superior localization accuracy compared to the conventional TDOA approach relying on the theoretical AE propagation velocity. The mean absolute error (MAE) for COLORS and TDOA were found to be 6.97 mm and 8.69 mm, respectively. Similarly, the root mean square error (RMSE) for COLORS and TODA methods were found to be 9.24 mm and 12.06 mm, respectively, indicating better performance of the COLORS algorithm in the context of source location accuracy. The finding underscores the significance of AE signal attenuation in minimizing AE wave velocity discrepancies and enhancing AE localization precision. The outcome of this investigation represents a substantial advancement in AE localization within laminated composite structures, holding potential implications for improved damage detection and structural health monitoring of composite structures.

Robust topology and discrete fiber orientation optimization under principal material uncertainty

This paper introduces a formulation of the robust topology optimization problem that is tailored for designing fiber-reinforced composite structures with spatially varying principal mechanical properties. Specifically, a methodology is developed that incorporates the spatial variability in the engineering constants of the composite lamina into the concurrent topology (i.e., material distribution) and morphology (i.e., fiber orientation distribution) optimization problem for the minimization of the robust compliance function. The spatial variability in the mechanical properties of the lamina is modeled as a homogeneous random field within the design domain by means of the Karhunen-Loe´ve series expansion, and is thereafter intrusively propagated into the stochastic finite element analysis of the composite structure. To carry out the stochastic finite element analysis per iteration of the optimization cycle, the first-order perturbation method is utilized for approximating the current state variables of the physical system. The resulting robust topology and fiber orientation optimization problem is formulated step-by-step for the minimization of the robust compliance function. With the view of solving the optimization problem at hand by means of gradient-based solution algorithms, the first-order derivatives of the involved design functions w.r.t. the associated design variables are analytically derived. The present work concludes with a series of numerical examples, focusing on the benchmark academic case studies of the 2D cantilever and the half part of the Messerschmitt-Bölkow-Blohm beam, aiming to demonstrate the developed methodology as well as to explore the effect that different parameterization instances of the random field bear on the predicted topology and morphology of the beams.

Multi-feature parallel topology optimization of fiber-reinforced coated structures based on a dual variable scale filtering method

Due to their outstanding mechanical properties, fiber-reinforced polymer composite (FRPC) structures have become a prominent research topic. Yet, to surpass existing performance limits, their design potential should be expanded beyond conventional empirical methods. Moreover, because of the high manufacturing costs, the protection of FRPC structures should be considered in the design phase to extend their service life. In this paper, we introduce an innovative configuration wherein metal coatings are strategically applied to the surfaces of FRPC structures. This technique aims to protect the internal matrix and fiber materials, and to inhibit the interlaminar delamination of composite laminates. Then, a corresponding full-scale topology optimization framework is built based on a density-based method. The coating, matrix, and fiber materials are considered collectively, avoiding issues such as excessive computation, non-convex optimization, and fiber discontinuity. Furthermore, a dual variable scale filtering (DVSF) method and its simplified scheme are presented to optimize coating thickness based on the physical information obtained from finite element analysis. Meanwhile, the co-evolution of solid topology and fiber morphology, driven by algorithms, facilitates the parallel optimization of multiple geometric features. Several typical examples, including wing ribs, are provided to illustrate the effectiveness and superiority of our approach, highlighting its engineering relevance.

Elasto-Plastic Constitutive Behaviour Prediction and Uncertainty Quantification of Damaged Composite Structure under High-Strain Rate Loading

Abstract The current research assesses the consequences of various damages (crack and delamination) and high-strain loading conditions on the fibre-reinforced composite structure's elasto-plastic stress-strain (EPSS) characteristics. The constitutive responses are obtained numerically (finite element discretization) using higher-order polynomials (to count the deformation) with the help of the MATLAB platform. The EPSS responses are evaluated via the modified Ludwik equation and Cowper Symonds model under high strain rate loadings. The model accuracy has been tested through the comparison between the present numerical and the published experimental data available in open domain. Furthermore, various numerical examples present the effect of damages (debond and/or crack), forces and stress-strain characteristics for a wide range of strain rates (ranging from 0.001 s−1 to 50 s−1). The stochastic constitutive model is obtained to show the modelling importance and the corresponding analysis parameters including the uncertainty quantification. Finally, a detailed understanding of the damages and geometries on the polymeric composite structure are enumerated via the delve model for the futuristic design.

Low-velocity impact performance of 3D-printed PLA/Epoxy/Glass fibers of composite structures and latches

The integration of 3D printing into the synthesis process of polymeric composite structures can offer significant advantages in producing geometrically complex parts. Moreover, engineering components may be subjected to impact loads that can adversely affect their performance and, in some cases, lead to failure. Traditionally, fiber-reinforced composite structures have demonstrated improved responses to applied mechanical loads. In this study, we designed multi-material polymer-based composite structures to enhance structural responses to impact loads. Employing fused filament fabrication (FFF) and solution casting methods, we manufactured PLA lattice infilled with epoxy/Milled Glass Fibers (MGFs) of composite structures with varied MGFs content ranging from 0 to 7.5 vol%. The research provides a comprehensive analysis of the impact behavior of glass-fiber reinforced composite structures, specifically focusing on PLA lattice frames filled with epoxy resin and varying levels of MGFs. Through low-velocity impact tests, the study assesses key parameters such as peak force, peak absorbed energy, residual velocity, and displacement, providing insights into the materials' response to impact loading conditions. The findings highlight the effect of MGF reinforcement on enhancing the impact toughness and resistance to crack propagation, with higher MGF content leading to improved mechanical properties. The microstructural analysis demonstrates the morphology and interface bonding of the composite materials, elucidating the mechanisms. Finally, latches were designed, and their impact behavior was tested to examine the usability of the composite structure in real-life components. The results suggest that the incorporation of MGFs in 3D-printed composite latches significantly enhances their impact resistance, with potential implications for various engineering applications.

Bone osteon-like structures: A biomimetic approach towards multiscale fiber-reinforced composite structures

Natural materials show astonishing mechanical properties, despite their rather poor building blocks. This counterintuitive behavior can be traced back to their hierarchical organization that enhances the properties of the building blocks. A classic example is bone: lightweight, stiff, strong, yet tough. This property combination is attributed particularly to the microstructure, where osteons deflect and arrest cracks. In this work, we mimic the bone microstructure with fiber-reinforced composites: we perform a numerical parametric study, by varying the layup of the osteon-like structures (OLS) and interconnecting layers representing the interstitial bone lamellae, and we manufacture and test single OLS as proof of concept. Results show the key role of OLS and interconnecting layers in deflecting and arresting cracks, whereas the combination of diverse materials affects the elastic properties. Finally, the introduction of hollow OLS, not affecting fracture toughness, might be used to expand the material functionality, paving the way toward novel multifunctional composites.

Innovative welding integration of acousto-ultrasonic composite transducers onto thermoplastic composite structures

Acousto-ultrasonic composite transducers (AUCTs), comprising piezoceramic materials in a reinforced polymeric matrix, show promise for structural health monitoring in composite structures. Challenges arise when integrating AUCTs onto highly loaded thermoplastic composites, especially low-surface-energy materials like polyaryletherketone composites. To address this, the study explores the viability of attaching AUCTs to low-melting polyaryletherketone carbon fiber-reinforced thermoplastic composite structures using ultrasonic welding. This welding technique forms a joint where the interface material fuses with the AUCT embedment and the structure matrix, providing a reliable and automatable process. The investigation includes a comparative analysis of an ultrasonic welded joint with an external energy director and a reference AUCT system integrated using a vacuum bagging oven procedure. Results highlight the potential of AUCT configurations integrated by ultrasonic welding as an alternative solution, acknowledging challenges that persist for further development and increased reliability in structural health monitoring applications.

4D printing and programming of continuous fibre-reinforced shape memory polymer composites

This study demonstrates the use of fused filament fabrication (FFF) 4D printing (4DP) to print programmable continuous fibre-reinforced composite (CFRC) structures with exceptional strength and eco-friendly features. This research focuses on bio-shape memory polymer composites (SMPCs) and employs experiments to fabricate lightweight CFRC parts using FFF technology. Different types of continuous fibres, including carbon fibre (CF), aramid fibre (AF), and fibreglass (FG), are incorporated into a biopolymer matrix made of biodegradable polylactic acid (PLA). The study evaluates microstructure, mechanical properties, and shape memory properties of SMPCs, employing techniques like cold and hot programming. Continuous fibres significantly enhance mechanical properties, increasing strength by over 1027.5 % in tensile tests and nearly 497.3 % in three-point bending tests. The research also addresses shape recovery and fixity ratios in 4D-printed SMPCs, finding a decrease when continuous fibres are incorporated into PLA. Notably, FGPLA specimens achieve the highest shape recovery ratio of approximately 95 ± 1 % after pure PLA. These findings highlight the potential of 4D-printed CFRCs in various applications, from human-material interaction to mechanical and biomedical fields. They contribute to sustainability by reducing material consumption and waste, demonstrated through the creation of reusable and lightweight items like hooks, lockers, finger splints, and meta-composites.

Failure mechanisms and process defects of 3D-printed continuous carbon fiber-reinforced composite circular honeycomb structures with different stacking directions

3D printing of continuous carbon fiber-reinforced composites relieves molds in composite manufacturing and gives flexibility to the design of lightweight and robust circular honeycomb structures. Nevertheless, how process defects affect the failure mechanisms of 3D-printed continuous carbon fiber-reinforced honeycomb structures remains undisclosed. To advance this research area, it requires a comprehensive investigation of the failure mechanisms and process defects of 3D-printed continuous carbon fiber-reinforced composite circular honeycomb structures (CCFRCCHSs), with particular attention to the influence of stacking orientations. In this study, 3D printing has been introduced to fabricate CCFRCCHSs using the identical composite material and geometry but different stacking orientations. Both in-plane and out-of-plane quasi-static compression experiments were carried out on these CCFRCCHSs. The mechanical properties and failure mechanisms were investigated through experimental analysis and cross-section observation, from which the microscopic voids and weak interfaces were identified as the dominating factors influencing the failure modes of CCFRCCHSs. This study provides insights into the association between process defects and failure mechanisms of 3D-printed CCFRCCHSs with different stacking directions, which offers guidance for the design of lightweight and robust composite circular honeycomb structures.

THE EFFECT OF GRAPHITE ADDITION ON THE FRICTION COEFFICIENT AND WEAR BEHAVIOR OF GLASS FIBER REINFORCED COMPOSITES

The use of fillers in fiber-reinforced epoxy matrix composites to enhance the wear performance of the composite is a widely employed method nowadays. In this study, the effect of incorporating graphite filler into a glass fiber-reinforced composite structure on the tribological properties of the composite was investigated. Composite materials produced using the hand lay-up method with three different levels of graphite filler were compared to unfilled composites in terms of wear behavior under different loads (7 N, 10 N, 15 N) and sliding distances (200 m, 400 m). The influence of load, filler content, and sliding distance on the friction coefficient and wear rate was discussed. When the results are examined, the significant effects of graphite filler on wear volume and friction coefficient are clearly observed. In the composite containing 12% graphite, the wear volume has decreased by almost 96%; this ratio has been around 93% for the composite with 4% graphite filler. As the reinforcement of graphite and force increase, the friction coefficient decreases, whereas with the increase in sliding distance, the friction coefficient declines. Microstructural analysis revealed that the filled composites exhibited less abrasion compared to the unfilled composites, and the surface porosity and craters were shallower.

A modified equally-spaced method (MEQS) for fibre placement in additive manufacturing of topology-optimised continuous carbon fibre-reinforced polymer composite structures

This study proposes a modified equally-spaced (MEQS) method for the path design of continuous fibres in additive manufacturing (AM) of topologically optimised composite structures. The MEQS method addresses the low fibre infill rate issue of the traditional Equally-Spaced (EQS) method by utilising the Offset method to generate looped printing paths around the internal cavities and gaps between continuous fibre paths. The developed MEQS method was first illustrated against EQS and Offset methods using an open-hole composite plate in which topology and material orientation were simultaneously optimised using the discrete–continuous parameterisation (DCP) method. Actual printing path-based finite element modelling showed that the MEQS method achieves a 25.32% increase in stiffness compared to the Offset method. Experimental testing of the additively manufactured open-hole composite plates showed that the MEQS method improves the stiffness and strength by 15.52% and 27.38%, respectively, compared to the Offset method. The proposed MEQS was further demonstrated through two other case studies by finite element modelling, showing that the stiffness of MEQS has increased by an average of 66.71% and 14.95% compared to EQS and Offset, respectively.

Processing and Analysis of Hybrid Fiber-Reinforced Polyamide Composite Structures Made by Fused Granular Fabrication and Automated Tape Laying

Fused granular fabrication (FGF) is a large format additive manufacturing (LFAM) technology and focuses on cost-effective granulate-based manufacturing by eliminating the need for semifinished filaments. This allows a faster production time and a broader range of usable materials for tailored composites. In this study, the mechanical and morphological properties of FGF test structures made of polyamid 6 reinforced with 40% of short carbon fibers were investigated. For this purpose, FGF test structures with three different parameter settings were produced. The FGF printed structures show generally significant anisotropic mechanical characteristics, caused by the layer-by-layer building process. To enhance the mechanical properties and reduce the anisotropic behavior of FGF structures, continuous unidirectional fiber-reinforced tapes (UD tapes), employing automated tape laying (ATL), were subsequently applied. Thus, a significant improvement in the flexural stiffness and strength of the manufactured FGF structures was observed by hybridization with 60% glass fiber-reinforced polyamide 6 UD tapes. Since the effectiveness of UD-tape reinforcement depends mainly on the quality of the bond between the UD tape and the FGF structure, the surface quality of the FGF structure, the interface morphology, and the tape-laying process parameters were investigated.

Buckling optimization of curvilinear fiber-reinforced composite structures using a parametric level set method

Buckling optimization of curvilinear fiber-reinforced composite structures using a parametric level set method