Fiber Reinforced Polymer Composites Research Articles

Effects of Absorption on the Tribological Properties of Carbon Fiber Reinforced Polyamide-6 Composites Manufactured by Fused Deposition Modeling

Abstract The present work studied the water absorption behavior of polymeric composite materials fabricated using 3D printing technology, as well as its effect on their tribological properties. Polyamide-6 was selected as the base matrix material. Short and continuous carbon fibers are used as the reinforced material. The results showed that the moisture absorption would impair the mechanical properties of polymer matrix and interface bonding between the fiber and the matrix. As a result, the tensile strength of the fiber reinforced polymer composites (FRPCs) decreases with water absorption. Nevertheless, the effects of moisture absorption on the wear properties of FRPCs are more complicated, which are depending on the fiber length and sliding conditions. With the short fiber reinforcements, moisture absorption deteriorated the wear resistance under all the testing conditions. With the increase of moisture level, more severe fiber damage/removal was observed, associated with the higher wear loss. With a relative high volume fracture of continuous carbon fiber (∼35 vol%), however, the wear resistance of the FRPC increased with moisture level, especially under a relatively low load. Based on microscopic observations, it was proposed that water inside FRPC specimens is able to provide the lubricating and cleaning effects, which contribute to a lower friction and smooth worn surfaces. The work provides new insights into designing and selecting printed polymer materials, subjected to different loading conditions.

Durable polymer composites preparation with oxy-delignified banana fiber for automotive parts: A study on mechanical and thermal properties

An innovative process route has been developed to produce modified banana fiber that are used as reinforcement in polypropylene composites for automotive parts. Banana fiber (BF) is modified through, Alkaline peroxide (APF), and oxygen delignification (ODF) treatment to obtain better adhesion and enhanced thermo-mechanical properties. The fiber-reinforced polymer (FRP) composites (10–30 % loading), were prepared through a specified configuration in a co-rotating twin screw extruder followed by injection molding. The results show that the ODF treatment with a 15 % NaOH concentration resulted in an 11-kappa number, which was lower than APF and untreated fiber. The highest improvement in tensile (31.27 ± 2.56) and flexural strength (44.880 ± 1.05 MPa) was achieved for ODF polymer composite and were 20.40 % and 35.6 % higher compared to the untreated fiber. The addition of natural fiber decreased the melt flow index to 7.56 gm/10 min with a slight decrease in hydrophilicity. The thermal stability was increased with enhanced melting, crystallization temperatures, and surface morphology.

Vertical z-axis discontinuous carbon fibers for improved lightning strike performance of continuous fiber-reinforced polymer composites

Effective lightning strike protection for critical aerospace and wind applications requires high electrical conductivity to dissipate current efficiently. However, polymer matrix composites face a challenge due to their inherently insulating nature. While conventional carbon fiber-reinforced composites (CFRP) exhibit electrical conductivity in the planar direction, achieving through-thickness conductivity remains an ongoing challenge. In this work, we have undertaken the fabrication of CFRP interleaved with vertically oriented carbon fibers (Z-fiber) to impart higher electrical conductivity along the thickness direction. Two Z-fiber composite variations are prepared: Z-1 with a single layer of Z-fiber and Z-5 with five interleaved layers and compared with no Z-fiber layer (Z-0) composite. The composite panels were subjected to lab-scale lightning strike tests with a current magnitude of 100 kA. To emulate real-world service conditions, an aerospace-grade paint coating was applied to the composite laminates. Comparative analysis shows Z-1 reduces damage diameter to ∼22 mm compared to Z-0 (∼26 mm), while Z-5 exhibits the least damage (∼16.7 mm), confirmed by optical microscopy. Z-5 demonstrates nine times higher through-thickness electrical conductivity than Z-0, reducing electrical anisotropy substantially. Thermal-electric finite element damage modeling predicts surface damage within 6% of experimental values for both Z-0 and Z-5 composites. Flexural tests post-lightning reveal Z-5 retains 66% flexural strength and 86% modulus, significantly better than Z-0, which retains less than 40% for both properties. This study highlights the efficacy of Z-fiber composites in lightning strike protection, offering improved through-thickness conductivity and mechanical property retention.

Enhancing mechanical performance of kenaf fiber reinforced polymer composites: influence of fiber characteristics and processing techniques

Enhancing mechanical performance of kenaf fiber reinforced polymer composites: influence of fiber characteristics and processing techniques

Machining-Induced Burr Suppression in Edge Trimming of Carbon Fibre-Reinforced Polymer (CFRP) Composites by Tool Tilting

Several challenges arise during edge trimming of carbon fibre-reinforced polymer (CFRP) composites, such as the formation of machining-induced burrs and delamination. In a recent development, appropriate-quality geometric features in CFRPs can be machined using special cutting tools and optimised machining parameters. However, these suitable technologies quickly become inappropriate due to the accelerated tool wear. Therefore, the main aim of our research was to find a novel solution for maintaining the machined edge quality even if the tool condition changed significantly. We developed a novel mechanical edge-trimming technology inspired by wobble milling, i.e., the composite plate compression is governed by the proper tool tilting. The effectiveness of the novel technology was tested through mechanical machining experiments and compared with that of conventional edge-trimming technology. Furthermore, the influences of the tool tilting angle and the permanent chamfer size on the burr characteristics were also investigated. A one-fluted solid carbide end mill with a helix angle of 0° was applied for the experiments. The machined edges were examined trough stereomicroscopy and scanning electron microscopy. The images were evaluated through digital image processing. Our results show that multi-axis edge-trimming technology produces less extensive machining-induced burrs than conventional edge trimming by an average of 50%. Furthermore, we found that the tool tilting angle has a significant impact on burr size, while permanent chamfer does not influence it. These findings suggest that multi-axis edge trimming offers a strong alternative to conventional methods, especially when using end-of-life cutting tools, and highlight the importance of selecting the optimal tool tilting angle to minimize machining-induced burrs.

Experimental Research on the Possibility of Changing the Adhesion of Epoxy Glue to Concrete

Among the many methods of joining different materials, gluing is characterized by its most specific nature. In comparison with, for example, welded, screwed, or overlapped connections, a glued connection depends on the largest number of factors. Many of them are related to the phenomenon of adhesion, which is complicated by definition. It has many shapes and forms, and its existence determines not only the durability of such a joint but also the possibility of its execution. Epoxy polymers are among the most commonly used adhesives. Their extremely good parameters can be easily modified by additives in the form of fillers. Compatibility between the filler and the adhesive allows for further improving the adhesive parameters in the glued joint. However, in order to effectively combine the adhesive and the filler, different, often specific mixing methods must be used. The following study presents the results obtained in an experimental research program, the aim of which was to increase the adhesion of epoxy resin to a properly prepared concrete substrate. As a method to increase the final adhesion, the addition of microsilica and carbon nanotubes in an experimentally determined amount was selected. The use of sonication as a mixing method together with cavitation allowed for improving the parameters which determine the final adhesion of the adhesive to concrete. The parameters which were selected to describe the course of changes in the adhesion of the adhesive to the concrete substrate were the viscosity, free surface energy, surface parameters, adhesion, and SEM images of the tested resin in various modification configurations. The obtained results make it possible to form stronger and more durable adhesive joints during the reinforcement of concrete structural elements using fiber-reinforced polymer (FRP) composites.

Analysis of aging effects on the mechanical and vibration properties of quasi-isotropic basalt fiber-reinforced polymer composites

Eco-friendly natural fiber composites, such as basalt fiber composites, are gaining traction in material science but remain vulnerable to environmental degradation. This study investigates the mechanical and vibrational properties of quasi-isotropic basalt fiber composites subjected to aging in two different environments: ambient (30 ºC) and subzero (-10 ºC), both in distilled water until moisture saturation. Aged specimens absorbed 8.66% and 5.44% moisture in ambient and subzero conditions, respectively. Mechanical testing revealed significant strength reductions in tensile, flexural, impact, and short beam shear tests, with ambient-aged specimens showing the largest decline (up to 31.7% in flexural strength). Vibrational analysis showed reduced natural frequencies, particularly under ambient conditions (27.27%). Sound absorption tests showed that pristine specimens had the highest transmission loss, while moisture-rich ambient-aged specimens had the lowest. SEM analysis confirmed surface degradation, with fiber pull-out and matrix debonding contributing to property loss. This research provides valuable insights into the environmental limitations of basalt fiber composites, emphasizing the need for enhanced durability in eco-friendly materials.

Utilization finite element and machine learning methods to investigation the axial compressive behavior of elliptical FRP-confined concrete columns

Nowadays, elliptical sections are among the geometric shapes that are becoming more and more popular in the architecture world. Finite element analysis (FEA) software, such as ABAQUS, is used to simulate elliptical concrete columns confined with fiber reinforced polymer (FRP) jackets based on experimental data published in the literature. The validity of the finite element modeling (FEM) approach was confirmed by comparing it to experimental data obtained from 45 specimens in existing studies, demonstrating a favorable agreement. Additionally, a parametric study was also carried out, which included simulating 40 more specimens, resulting in a total of 85 specimens for analysis. The effect of various test variables such as sectional aspect ratio, the amount of FRP layers, and concrete strength on the elliptical column’s behavior is investigated. The axial compressive strength is predicted using current models from the literature. The outcomes revealed that the higher unconfined concrete strength decreased FRP confinement efficacy. Insufficient confinement with post-peak softening is more likely in FRP-confined high strength concrete columns, especially if the confinement was not stiff enough. Also, by adding more FRP layers, the stress and strain capabilities of elliptical concrete columns confined with FRP composites are improved. Physical experiments require a significant investment of time and resources, but they can produce valuable results. Finite element analysis, on the other hand, depends heavily on the modeler's competence and can minimize the number of experiments required by employing computer simulation, but it also requires high computer settings. In recent years, there has been a major advancement in the usage of machine learning (ML) algorithms in the applications of FRP composites with different concrete components. Taking this into consideration, this investigation is extended to estimate the compressive strength of elliptical FRP-confined columns using four tree-based ML algorithms including Decision Tree, Random Forest, Gradient Boosting and XGBoost. The XGBoost model achieved the highest predictive accuracy with the R2 values of 0.95 for both the compressive strength and axial strain targets.

Highly protective and functional strengthening strategies for 3D printed continuous carbon fiber reinforced polymer composites: manufacturing and properties

Carbon fiber-reinforced polymer (CFRP) composites have gradually emerged as a crucial material in the aerospace industry. However, inadequate impact resistance and thermal stability limit survival in extreme environments. Inspired by the specific functions of multiple layers of tissue, from bird feathers to the musculoskeletal system. We propose low-cost composite strengthening strategies and efficient novel three-dimensional graphene aerogel manufacturing methods. A novel graphene aerogel/carbon fiber reinforced polymer (GAC) composite prepared by in-situ laser-induced graphene (LIG) layers on the surface of 3D-printed CFRP. GAC composites enhance CFRP's impact protection, thermal insulation, and electromagnetic shielding capabilities. For protection, GAC composites reduce low-velocity impact damage by 26.2%. The graphene layer can increase the thermal buffering capacity of the material four times, and the long-term service temperature can be increased by 40% compared to traditional CFRP. For functionality, the composites enable electromagnetic interference (EMI) shielding effectiveness of up to 50.2 dB. Furthermore, it can achieve surface heating above 400 °C and rapid de-icing through electrothermal effects. The simple and efficient processing method of GAC composites and tunable functionalities holds promise for the development of highly protective and intelligent aircraft skins.

Experimental Testing of Shear Web Panels of Steel Plate Girders Strengthened by Fiber-Reinforced Polymer Composites

Experimental Testing of Shear Web Panels of Steel Plate Girders Strengthened by Fiber-Reinforced Polymer Composites

Evaluating mechanical performance of coconut fibre reinforced polymer composites with variable fibre content

The rapid growth of composite materials, leveraging natural ingredients such as dried fruit, rice husk, wheat husk, straw, and hemp fibres, has expanded their applications and market presence. Among these, coconut fibre stands out due to its high tensile strength, making it a promising reinforcement for polymer composites. However, increasing the coconut fibre content can reduce the cohesion and some properties of the composites. This study investigates the impact of the weight percentage of coconut fibres on the mechanical properties of coconut fibre-reinforced composites. Various composites were prepared with different weight percentages of coconut fibre, and their mechanical properties were evaluated using tensile tests with a Universal Testing Machine Instron 8872 and hardness tests with a Digital Shore Scale “D” Durometer. The results indicate significant changes in tensile strength, tensile strain, and hardness corresponding to the weight percentage of coconut fibre. This research highlights the importance of optimizing fibre content to achieve balanced mechanical properties in coconut fibre-reinforced composites.

Numerical study of delamination process of the CFRP composite

A quasi-static approach for an interface damage model, incorporating Rayleigh damping for viscoelastic carbon fiber reinforced polymer composites, is introduced. The interface traction-relative displacement behavior is modeled using a thin adhesive layer, similar to cohesive zone models. The problem is solved numerically with a semi-implicit time-stepping method. The cohesive interface model, integrated into the Finite Element Method, was applied to determine the critical force away from the crack tip. Results showed that the numerical delamination under mode I conditions aligned well with experimental data for the cohesive zone formulations studied. The numerical example demonstrates the effectiveness of the proposed model.

A multi‐layer approach for additive manufacturing of continuous fiber composites

AbstractAdditive manufacturing (AM) of continuous fiber reinforced polymer composites (cFRPCs) requires innovative tool‐pathing strategies that account for the anisotropic properties of the continuous fibers and ensure their continuous deposition as reinforcement along the designed structure, reducing fibers bending and cutting. Existing 3D printing slicing software, designed for isotropic materials like neat polymers, has been adapted for 3D printing of continuous fiber composites, resulting in a layer‐by‐layer approach that necessitates filament cutting after each layer deposition. This method introduces discontinuities, weakening the material and underutilizing continuous fibers strength. In this research, we propose a novel tool‐pathing strategy designed to address these challenges through (1) Ensuring fiber continuity across layers by allowing overlapping filaments and (2) Strategically positioning fiber cut points based on stress distribution, modeled using finite element analysis. A Multi‐Layer Continuous Fiber Path (ML‐CFP) approach was introduced and validated on a simple bracket structure featuring two load‐application inserts. 3D printed brackets using different tool paths were tested to failure under tension and compression after compression molding to improve interlayer adhesion. Mechanical investigations confirmed that the ML‐CFP approach enhances fiber utilization, improving tensile strength and work to fracture by up to 46% and 100% through promoting failure in fibers rather than at cut points.Highlights Introduced the multi‐layer continuous fiber path method (ML‐CFP) in AM of cFRPCs. Introduced the strategic cut point placement (SCPP) based on stress distribution. Maintaining fiber continuity and reduce fiber bending by allowing filament overlap. Mechanical testing to compare the ML‐CFP with conventional slicing methods. Enhanced tensile strength by up to 46% and work to fracture by 100%.

Improvement of curing efficiency and heat resistance of CFRP by the growth of SiCNWs on CF

Carbon fiber-reinforced polymer composites are widely used in modern industry. However, poor heat transfer between layers of carbon fiber cloth during the curing process leading to poor curing of the substrate, long curing cycles, and excessive heat accumulation has become an urgent problem to be solved. A common approach is dispersing highly thermally conductive fillers in the polymer matrix to improve the curing efficiency of the composites. Different from adding fillers, we report a novel method of in situ growth of SiC nanowires (SiCNWs) on the surface of carbon fiber (CF) by the chemical vapor deposition (CVD) method and study the effects of CVD deposition time on curing efficiency and thermal stability of the composites. The results indicate that the nano bridge effect of SiCNWs significantly improves the curing efficiency of the composites. Compared with pure CF/epoxy composites, the curing efficiency can be increased by 38.72%. The cross-linking point between SiCNWs and the resin matrix enhances the thermal stability of the composites and increases the heat resistance index ( T HRI) by 8.4°C.

Finite Element Analysis of Two-Way Reinforced Concrete Slabs Strengthened with FRP Under Flexural Loading

This paper presents a finite element (FE) model of reinforced concrete two-way slab strengthened using fiber-reinforced polymer (FRP) sheets. This model was validated against experimental data from the literature and it showed acceptable prediction accuracy. Although carbon-FRP (CFRP) is the most commonly used composite in repairing and strengthening reinforced concrete structures, it is important to consider other types of FRP composites such as the eco-friendly basalt-FRP (BFRP) and the newly developed polyethylene terephthalate-FRP (PET-FRP). Therefore, the validated FE model was utilized to perform a parametric study for slabs having different values of concrete compressive strength (ranging from 20 to 80 MPa) and strengthened with other types of FRP. The results show that CFRP provides the highest strength enhancement with a 34.5% increase in the ultimate load, while PET-FRP provides the lowest improvement with an increase of 11.2%, compared with unstrengthened slab. The results also show that the concrete compressive strength (fc’) has moderate influence on the ultimate load. For example, increasing fc’ from 20 MPa to 80 MPa increased the predicted ultimate load for CFRP-strengthened slab from 15% to 62%. The FE model provides a suitable prediction for the ultimate strength and deformability of the strengthened two-way slabs that helps in better understanding of the performance of strengthened slabs and allows engineers to optimize design parameters.

Questioning the Representativeness of Damage Mechanisms in Single-Fiber Composites via In Situ Synchrotron X-Ray Holo-Tomography.

In fiber-reinforced polymer composites, the fiber-matrix interface controls stress transfer mechanisms, thereby affecting mechanical performance. Interfacial properties are often extracted via single-fiber composite tests. In these tests, the load is transferred from the polymer to the fiber through interfacial shear stresses, necessitating the evaluation of interfacial shear properties. To adopt these properties in the design of industrially relevant composites, one must assume that the damage mechanisms in single-fiber composites are representative of those in multi-fiber composites, consisting of highly aligned, unidirectional plies with high fiber volume fractions. That assumption, however, has never been validated. In this paper, the real-time damage development is monitored in single-fiber and multi-fiber composites using in situ X-ray holo-tomography at 150-nm pixel size. The technique enables the first-ever 3D detection of longitudinal interfacial debonding in carbon and glass single-fiber composites. This mechanism is not detected in multi-fiber composite specimens, suggesting that single-fiber composites are intrinsically unrepresentative of realistic composite behavior.

Structure‐function integrated design of electromagnetic interference shielding and mechanical properties of 2D carbon fiber reinforced polymer composites based on absorption loss regulation

Structure‐function integrated design of electromagnetic interference shielding and mechanical properties of <scp>2D</scp> carbon fiber reinforced polymer composites based on absorption loss regulation

Additive manufacturing of continuous carbon fiber reinforced polymer composites using materials extrusion process. Mechanical properties, process parameters, fracture analysis, challenges, and future prospect. A review

Additive manufacturing of continuous carbon fiber reinforced polymer composites using materials extrusion process. Mechanical properties, process parameters, fracture analysis, challenges, and future prospect. A review

In-situ experimental characterization and numerical investigation of the crack initiation of SMC composite under uniaxial tension

This paper explored the crack initiation of sheet molding compound (SMC) composite under uniaxial tensile loads by integrating in-situ experimental characterization and subsequent numerical analysis. Firstly, a synchrotron micro-X-ray computed tomography was utilized to character the morphology and evolution of the microstructure and fracture features of the SMC sample with different loading conditions. Meanwhile, the digital volume correlation technology was employed to determine the internal three-dimensional deformation. Then, a numerical analysis was conducted to describe the relationships among the microstructure, deformation distribution, and position of the crack initiation. Finally, a predictive model was developed based on the internal microstructure and the deformation distribution and then utilized to predict the location and sequence of crack initiation. The good agreement between the predicted results with the experimental ones reveals the feasibility of the proposed model in exploring the fracture behaviors of carbon fiber reinforced polymer composites with complex internal microstructure.

A thermodynamically‐based fractional model combined viscoelastic‐viscoplastic‐ductile damage with application to fiber‐reinforced polymer composites

AbstractA thermodynamically‐based fractional viscoelastic‐viscoplastic‐damage constitutive model combined with continuous damage mechanics (CDM) theory was established, in order to describe the rate‐dependent nonlinear behavior of fiber‐reinforced polymer composites (FRPCs). The fractional Helmholtz free energy consists of four contributions: viscoelastic (VE), viscoplastic (VP), hardening and damage, in which the VE and VP parts are constructed by fractional Zener and Scott‐Blair (SB) element forms respectively. The constitutive equation is obtained through Helmholtz free energy for the fractional Zener model, and plastic flow and hardening evolution law are all derived in the process. The ductile damage, coupled to both VE and VP free energy parts, is introduced through fractional damage energy release rates to model the degradation of material properties. The corresponding strain energy release rate and dissipation contributions are also derived. The fractional implicit time integration algorithms of proposed model are presented. The model is applied to validate tests of FRPCs under various loading conditions. The model validation and comparison are presented by simulating experimental data and existing models in the literature. And the corresponding evolution of dissipated energy is discussed to further valid the characterization ability of the model.Highlights A thermodynamical fractional constitutive model was developed for FRPCs. The Helmholtz free‐energy potential for fractional Zener model is adopted. The physical significance of fractional order parameters is explored. Fractional implicit integration algorithm of proposed model is implemented. The validation and comparison of the model are presented under various loads.