Glass Fiber Research Articles

Cross-Scale Industrial Manufacturing of Multifunctional Glass Fiber/Epoxy Composite Tubes via a Purposely Modified Filament Winding Production Line.

In the present research work is demonstrated a cross-scale manufacturing approach for the production of multifunctional glass fiber reinforced polymer (GFRP) composite tubes with a purposely redesigned filament winding process. Up until now, limited studies have been reported towards the multiscale reinforcement direction of continuous fibers for the manufacturing of hierarchical composites at the industrial level. This study involved the development of two different multi-walled carbon nanotube (MWCNT) aqueous-based inks, which were employed for the modification of commercial glass fiber (GF) reinforcing tows via a bath coating unit in a pilot production line. The obtained multifunctional GFRP tubes presented a variety of characteristics in relation to their final mechanical, hydrothermal aging, electrical, thermal and thermoelectric properties. Results revealed that the two individual systems exhibited pronounced differences both in crushing behavior and durability performance. Interestingly, for lateral compression the MWCNT coatings comprising a polymeric dispersant minorly affected the mechanical response of the produced tubes. The crashworthiness indicators of the multifunctional tubes displayed a slight 5% variation to the respective reference values, combined with a more ductile behavior. Moreover, regarding the bulk electrical and thermal conductivity values, as well as the Seebeck coefficient factor, the corresponding tubes displayed a variance of 233% and 19% and an opposite semi-conducting sign denoting a p- and n-type character, respectively.

Establishment of collection methods and laboratory testing methods for active pharmaceutical ingredient in the workplace air

Objective: To establish collection methods and laboratory testing methods for qualitative and quantitative analysis of 9 typical active pharmaceutical ingredient in the workplace air. Methods: In December 2021, a mixed solution of nine analytes was prepared and then dispersed in aerosol state to simulate sampling. Glass fiber filter membrane was selected as air collector and collected active pharmaceutical ingredient in the air at a rate of 2.0 L/min for 15 minutes. Then, the obtained filter membrane samples were eluted with 25%ACN/75%MeOH. Finally, the eluent was qualitatively and quantitatively analyzed with liquid chromatography-triple quadrupole mass spectrometer. Results: This method could effectively collect active pharmaceutical ingredient in the air, with an average sampling efficiency of more than 98.5%. The linear correlation coefficient r was greater than 0.9990. The lower limit of quantification for each analyte ranged from 0.6~500.0 ng/ml, and the average recovery rate ranged from 97.6%~102.5%. Conclusion: This method could simultaneously collect 9 active pharmaceutical ingredient in the workplace air, and could provide accurate qualitative and quantitative analysis in subsequent laboratory tests.

Numerical simulation of composite materials with sisal and glass fibers for ballistic impact resistance

Numerical simulation of composite materials with sisal and glass fibers for ballistic impact resistance

Bond behavior between recycled macro fibers and ultra-high-performance concrete matrix: Tests and property characterization

A green and cost-efficient ultra-high-performance concrete (UHPC) has been proposed using discrete macro fibers recycled from waste glass fiber reinforced polymer (GFRP). The tensile properties of such composites are significantly affected by the macro fiber/UHPC bond properties. However, there is very little work characterizing the bond properties of the macro fiber/UHPC interface. Furthermore. lack of study focused on the methods for macro fiber surface treatment and their effects on macro fiber/UHPC interfacial bonding. Therefore, the present study first carried out pullout tests in two series consisting of 128 pullout specimens. Series 1 aimed to characterize the bond behavior of the macro fiber/UHPC interface, while Series 2 aimed to investigate the effect of surface-modifying agents on macro fiber/UHPC interfacial bonding. The results demonstrated that the bond strength increased from 19.3 to 20.9 MPa when the embedded length of the 8 mm-wide fiber increased from 5 to 10 mm. The modification of neutral Nano SiO2 (NNS) enhanced the bond strength by up to 20.5 %, while alkaline Nano SiO2 (ANS) and silane coupling agent (SCA) showed a negative effect on bond strength. Then, the shear-lag theory was utilized for predicting the pull force-slip curves of the fibers embedded in UHPC, and then the bond parameters of the interfaces were obtained through an inverse analysis. A good agreement is exhibited with integral absolute error (IAE) from 4.5 % to 10.5 % between predicted results and test results.

Functional modification of softwood fiber and its application in natural fiber-based sound-absorbing composite

Natural fiber-based sound-absorbing materials have received more and more attention due to the increasingly severe noise pollution. However, the current natural fibers’ sound-absorbing materials often have poor flame-retardant performance and degradability, which limits their further application. In this study, flame-retardant cellulose fiber (FRCF) was prepared by modifying softwood fiber, and a kind of fiber-based sound-absorbing material, natural fiber-based sound-absorbing composite (NFSC), was prepared by replacing glass fiber with FRCF. The results show that the synthesis of FRCF is successful, and the functional groups containing phosphorus and nitrogen introduced into the cellulose side chain can significantly improve the thermal stability of softwood fiber. FRCF is able to bestow initial flame-retardant capability on the NFSC, allowing NFSC to get the V-1 level in vertical burning test with fewer flame retardants, and the limiting oxygen index (LOI) of NFSC can reach 28.5 %. The NFSC with FRCF instead of glass fiber also has better sound absorption performance; its maximum sound absorption coefficient reaches 0.90, and its noise reduction coefficient (NRC) reaches 0.45. This work is expected to provide inspiration for the design and preparation of environmentally friendly natural fiber-based sound-absorbing materials.

Sustainable mortar reinforced with recycled glass fiber derived from pyrolysis of wind turbine blade waste

Pyrolysis technology has recently made significant progress in recycling millions of tons of wind turbine waste (WTB). Short fibers represent its main product (∼70 wt%), which needs further studies to explore its future applications. In this context, this work aims to the valorization of the recycled glass fiber (rGF) derived from pyrolysis of WTB (at 550 °C) in the production of rGF-reinforced mortar composite (rGF/M) for sustainable building applications. The research began by subjecting the derived rGF to sieving (rGFs), washing (rGFw), and oxidation (rGFo) pretreatments for purification and removing any impurities, organic residues, and char particles. Afterward, the chemical degradation of the treated rGF in a strong alkaline cement solution with pH = 14 was studied for up to 90 days. In parallel, the mortar composite samples were fabricated at 1 wt% of the treated rGF batches (rGFr, rGFw, and rGFo) to study the effect of different pretreatments on their microstructure, dispersion, compressive strength, flexural strength, and water absorption capabilities behavior after different curing periods (28 and 90 days). The results showed that rGFo (7.84%) showed a lower degradation rate versus rGFw (16.41%) and rGFr (30.76%). Meanwhile, the highest curing period (90 days) contributed to improving the properties of the mortar composites in general, especially in the case of using rGFo which led to improved compressive strength (15%) and reduced absorption coefficient (38%) and cumulative water content (32%) with a uniform distribution of short fibers in the matrices and a slight increase in flexural strength compared to control mortar sample (8.6 MPa). While rGFs provides better flexural strength (9.3 MPa) with a 12% improvement. Based on these results it can be concluded that rGFo has high potential in sustainable building materials with high competition with virgin glass fiber.

MECHANICAL CHARACTERIZATION AND IMPACT RESISTANCE OF A NOVEL HYBRID COMPOSITE BASED ON SALVADORA PERSICA ROOTS AND GLASS FIBERS

The observation of fibers in salvadora persica roots inspired us to consider the idea of using them as reinforcement to create an innovative composite. The current work focuses on the volumetric mass density, extraction, molding, and mechanical testing of composites and hybrid composites made from salvadora persica roots and glass fibers reinforced with two types of polyester matrix, chosen due their characteristics suitable for use in different orientations. Various extraction and combination methods have been used to identify an optimal approach for obtaining fibers from salvadora persica roots, considering its chemical composition (hemicellulose, pectin, and lignin). In this investigation, the hand lay-up method was used to mold specimens with different geometries. The composite and hybrid composite were combined with a polyester matrix and subjected to various mechanical tests namely; tensile, impact resistance, and water absorption. The results indicate that reinforcing polyester resins with SP fibers, whether long or short, enhances the overall mechanical properties of the composite. Additionally, improved adhesion between salvadora persica roots fibers and resin was observed.

Enhancing the thermal and mechanical properties of sulfonated peek fiber composites with reduced smoke density and toxicity

AbstractPolyether ether ketone (PEEK) sulfonation process is a reasonably easy but time‐consuming to manufacture composites. This study focuses on altering PEEK powder in a sulfuric acid solution via a sulfonation process to develop sulfonated PEEK (SPEEK) resin for the fiber‐reinforced thermoplastic composite manufacturing and characterization steps. In this study, about 5 wt% PEEK powder was sulfonated in 98% sulfuric acid solution for 12 h at 65°C. The water bath technique was used for the precipitation process to obtain the SPEEK polymer. After proper washing and drying, the SPEEK matrix (resin) was obtained by dissolving it in dimethylformamide in a ratio of 1:2. This resin solution was then used to manufacture thermoplastic Kevlar and glass fiber‐reinforced composites employing wet layup process and cured at an elevated temperature under pressure. These SPEEK composites passed the flame retardancy UL94 test with a V0 rating. The average water contact angle of the glass fiber‐ and Kevlar‐SPEEK composites is 93.67° and 102.24°, respectively. The average tensile strength values of these composites were found 222.22 and 284.35 MPa, correspondingly. The smoke density and toxicity tests of the glass fiber‐SPEEK composite confirmed lower smoke generation with the modifications. These SPEEK‐fiber composites can be considered for various industrial applications, including aviation, energy, drone, defense, and automotive.

Effect of synergistic action of anodising and graphene on the mechanical properties of fibre-reinforced metal laminates

Fibre reinforced metal laminates (FMLs) are widely used in various fields due to their excellent properties. However, the weak interlayer properties of FMLs limit their applications. In this paper, the interlayer properties of FMLs are enhanced by anodising the 2024-T3 aluminium alloy layer in FMLs or by epoxy matrix modification of graphene nanoplatelets (GNPs). The effect of both synergistic impacts on the interlayer properties of most FMLs is investigated. The FMLs were manufactured using the wet lay-up technique using 2024-T3 aluminium alloy, E51 epoxy and EW100 glass fibre. The results showed that the type I fracture toughness, tensile strength, flexural strength, interlayer shear strength and single layer shear strength of FMLs after anodic oxidation treatment were increased by 406.4%, 10.3%, 18.3%, 42.6% and 28.3%, respectively, compared with those of pure FMLs. The type I fracture toughness, tensile strength, flexural strength, interlayer shear strength and single layer shear strength of the GNPs-modified FMLs matrix were increased by 280.4%, 3.7%, 6.8%, 34.5% and 19.1%, respectively, compared with those of pure FMLs. Moreover, the synergistic effect of FMLs indicates that the simultaneous anodic oxidation and GNPs modification of FMLs can lead to the best mechanical properties of FMLs. Microscopic images and schematics illustrate the toughening mechanism of anodising and GNPs, including the enhancement of aluminium/resin interface and fibre/resin interface and the enhancement of resin matrix properties.

Environmentally Sustainable Raised Access Flooring Product Development

Raised access floors are nowadays widely used in buildings. A novel raised access flooring product is developed by this research, with a set of sustainable features, including less environmental impact and high strength. Its floor panels are made of polyurethane (PU) reinforced with glass fibre, which is light-weight and fire-resistant, replacing the traditional floor panel materials, and the panels are supported by simplified steel stringers to reinforce the strength of the flooring product. Instead of the conventional sandwich design consisting of a core material encapsulated by outer layers, the new floor panel design adopts the reinforced PU as its sole material, which not only simplifies the structure but also reduces floor weight and costs. The sustainable advantage is further approved by the environmental life cycle assessments of the new raised flooring product in comparison to traditional ones made of cement and woodchips, with results showing that the new floor product’s total environmental impact is 52% less than cement floor and 47% less than woodchip board floor. Further, the finite element analysis (FEA) was carried out, and the experimental test was conducted to verify the FEA results, indicating that the new product’s strength is higher than the requirements of the raised access flooring product standards. There is no raised access flooring product made of PU reinforced with glass fibre available in the market, and, hence, the new product developed by this research is a novel contribution.

The effect of printing parameters on the mechanical properties of fiber-reinforced PA6 matrix composites in material extrusion-based additive manufacturing

PurposeThis study aims to understand the effect of the use of different proportions and types of fibers in the polyamide 6 (PA6) matrix during material extrusion-based additive manufacturing (MEX) and the effect of the manufacturing parameters on the mechanical properties. The mechanical, thermal and morphological properties of PA composites that are reinforced with carbon fiber (CF), glass fiber (GF) and as well as hybrid fiber (HF) were investigated.Design/methodology/approachIn this study, the effect of nozzle temperature and layer thickness on the mechanical properties of composite samples was investigated in terms of their behavior under tensile, impact and compression loads, manufacturing parameters as well as fiber ratio and type. The results were also consolidated by scanning electron microscopy.FindingsAt 20 Wt.% CF reinforcement PA6 samples, a tensile strength value of 125 MPa was obtained with a 60% increase in tensile strength value compared to neatPA6. The HF-reinforced ones also measured a tensile strength value of 106.69 MPa. This corresponds to an increase of 38% compared to neatPA6. The results also show that HF reinforcement can be an important component for many composites and a suitable material for use under compression loading.Originality/valuePA6, an engineering polymer, can be produced by MEX, which offers several advantages for complex geometries and customized designs. There are studies on different carbon and GF ratios in the PA6 matrix. Using these fibers together in a HF, the examination of their mechanical properties in the MEX method and the examination of the effect of GF reinforcement in the hybrid structure, which has a cost-reducing effect, has been an innovative approach. In this study, the results of the optimization of the parameters affecting the mechanical properties in the production of samples reinforced with different ratios and types of fibers in the PA6 matrix by the MEX method are presented.

Experimental study on the effects of SS304 and Aluminium reinforcements on mechanical and vibration properties in jute‐epoxy composites

AbstractJute fiber has emerged as a promising reinforcement material in polymer composites, and researchers are actively exploring hybrid composite materials to overcome its individual mechanical property limitations and enhance overall performance. The paper introduces a unique hybridization of polymer composites that harnesses the advantages of stainless steel and aluminium offering a lightweight material for potential engineering applications. In this study, stainless steel 304 wire mesh (S), aluminium wire mesh (Al) and aluminium perforated sheet (Alp) are used as an additional reinforcement along with jute (J) and glass (G) fibers to fabricate hybrid polymer composites with varying volume fractions of SS304 and Al wire mesh. Seven laminates of hybrid composites namely J/J/J/S/J/J/J, J/J/S/J/J/S/J/J, J/J/J/Al/J/J/J, J/J/Al/J/J/Al/J/J, J/J/J/Alp/J/J/J, G/J/J/J/S/J/J/J/G, (J/J/S/J/J/S/J/J)450 along with virgin composite laminate J/J/J/J/J/J/J/J were fabricated and tested to obtain mechanical and vibration properties. Bonding between metal wire and matrix is investigated and reported through ILLS tests and SEM observations. Experimental findings indicate a notable 24% and 7% increase in tensile and ILSS strength, respectively, with SS304 reinforcement. Moreover, significant improvements in flexural and impact strength, approximately 48% and 33% for J/J/S/J/J/S/J/J, demonstrate the effectiveness of the hybrid approach. The J/J/S/J/J/S/J/J laminate excels in damping capacity under various boundary conditions. The study underscores the potential of metallic reinforcement to enhance the mechanical properties of jute fiber‐reinforced polymer composites, presenting opportunities for the development of lightweight, sustainable, and high‐performance materials in engineering applications.Highlights Developed jute fiber‐based hybrid polymer composites with metal wire reinforcement. Significant increase in strength and stiffness observed with addition of metal wires. Bonding between metal wire and matrix is investigated through ILLS tests and SEM observations. Vibration damping of all hybrid materials is reported. Study provides valuable data to develop sustainable, lightweight, and cost‐effective materials.

Lifecycle Assessment of Strategies for Decarbonising Wind Blade Recycling toward Net Zero 2050

The wind energy sector faces a persistent challenge in developing sustainable solutions for decommissioned Wind Turbine Blades (WTB). This study utilises Lifecycle Assessment (LCA) to evaluate the gate-to-gate carbon footprint of high-profile disposal and recycling methods, aiming to determine optimal strategies for WTB waste treatment in the UK. While this article analyses the UK as a case study, the findings are applicable to, and intended to inform, recycling strategies for WTB waste globally. Long-term sustainability depends heavily on factors like evolving energy grids and changing WTB waste compositions and these must be considered for robust analysis and development strategy recommendations. In the short to medium term, mechanical recycling of mixed WTB waste is sufficient to minimise Global Warming Potential (GWP) due to the scarcity of carbon fibre in WTB waste streams. Beyond 2040, carbon fibre recycling becomes crucial to reduce GWP. The study emphasises the importance of matching WTB sub-structure material compositions with preferred waste treatment options for the lowest overall impact. Future development should focus on the extraction of carbon fibre reinforced polymer (CFRP) structures in WTB waste streams, commercialising large-scale CFRP structure recycling technologies, establishing supply chains, and validating market routes for secondary carbon fibre products. In parallel, scaling up low-impact options, like mechanical recycling, is vital to minimise WTB waste landfilling. Developing viable applications and cost-effective market routes for mechanical recyclates is necessary to displace virgin glass fibres, while optimising upstream recycling processes based on product requirements.

Relationship between deflection basin parameters and backcalculated pavement layer moduli

In the case analysed, a glass fibre mesh was applied under the asphalt layer during a rehabilitation treatment. Because only one lane was reinforced, the test section can be used to observe the influence of glass fibre mesh on the relationship between the selected deflection basin parameters (RoC, BLI, MLI, and LLI) and back-calculated pavement layer moduli. The FWD measures were used to determine the bowl of deflection indicators and to back-calculate the layer’s moduli. The values of DBP-s allowed confirmation of the technical condition of pavement construction. The first measures were carried out in 2019 and repeated in 2021; the results were then compared and analysed. Influence was observed on the relationship between the deflection basin and moduli, especially for the base course and subgrade. The reinforced lane showed a better coefficient of determination between DBPs and moduli in 2019, but in 2021 relationships were observed only for LLI and subgrade moduli. The unreinforced lane, however, showed the mentioned relationships in both 2019 and 2021. Because of a relatively small number of measurement points, the presented analyses and observations should be considered as preliminary. Presented results and relationships are another step into developing an alternative approach to determining the initial pavement moduli i.e. to use as a seed moduli.

From Waste to Renewables: Challenges and Opportunities in Recycling Glass Fibre Composite Products from Wind Turbine Blades for Sustainable Cement Production

The progress of civilization, driven significantly by the widespread adoption of electricity, has impacted various aspects of life, from household operations to industrial activities. Consequently, there has been a notable increase in waste production across different sectors of the economy. Among used materials, composite products reinforced with glass fibres stand out due to their prevalent use in numerous industries. While offering strength and durability, they pose disposal challenges due to their complex composition, making recycling difficult and contributing to waste accumulation in landfills or to environmental contamination. Industrialised nations wrestle with balancing economic growth and environmental sustainability, aiming to reduce the ecological footprint of industrial activities. Efforts to promote recycling, develop alternative materials, and improve waste management practices are crucial for mitigating the environmental impact of civilisation’s progress. This article presents methods of disposing of post-operation wind turbine blades, focusing on recycling glass and glass fibre as secondary raw materials. We discuss technological, normative, and economic challenges and emphasise the need for ongoing research and innovation in waste management practices. We examine the use of glass and glass fibres in cement production and advocate for sustainable principles in the renewable energy industry, aligning industrial endeavours with ecological sustainability for a greener future.

Study on microwave absorption performance of the skin‐core dual‐domain structure constructed with thin‐ply laminate and honeycomb

AbstractThis study introduces an innovative approach to enhance the absorption capabilities of skin‐core dual‐domain structure radar‐absorbing materials (SDSRAM) composed of thin‐ply laminates and honeycomb. The upper skin laminates consist of transmissive skin and impedance matching layer. The impedance matching layer was hot‐pressed using functionalized absorbed thin‐ply glass fibers prepregs, flaked carbonyl iron powder (FCIP) and multi‐walled carbon nanotubes (MWCNTs) as the absorber. The lower skin was manufactured using carbon fiber‐plated nickel. The core is prepared by honeycomb modified (HCM). The permittivity and permeability of the skin laminates and the HCM were measured by wave‐guide method. The impact of FCIP/MWCNT on the electromagnetic (EM) parameters of the thin‐ply laminates and the influence of MWCNTs on the permittivity of the honeycomb were investigated. Microwave absorption properties of SDSRAM were assessed through the measurement of reflection loss (RL) using the arch method and simulated using the microwave simulation software CST studio suite 2020. Experimental verification was conducted to confirm the absorbing performance. The results show that the effective absorption bandwidth (RL < 10 dB) of SDSRAM covers the frequency range of 2.2–18 GHz, with a maximum absorption intensity of −42.5 dB. The introduction of the thin‐ply laminates caused a shift in the peak of the reflectance curve toward lower frequencies.Highlights Functionalized absorbed glass fibers were prepared using fiber spreading functional sizing integrated process. A new skin‐core dual‐domain synergistic modulation absorbed structure was developed with thin‐ply laminates and modified honeycomb. Its broadband absorption mechanism was discussed. Desired broadband absorption performance was acquired with thin thickness.

Assessment of crack suppression in glass/epoxy curved laminates by incorporating micro and nanofillers

AbstractThe design of structures with a large radius of curvature is challenging because fiber‐reinforced composite materials have low resistance to delamination in the direction perpendicular to their thickness. These structures are commonly found in a wide variety of structural components that are used in the wind turbine and aviation industries. The objective of this study is to conduct an experimental investigation into the efficacy of incorporating milled glass fiber, cellulose nanoparticles, and carbon nanoparticles as fillers into an epoxy matrix to improve the resistance to delamination of glass/epoxy curved laminates and thereby inhibit crack growth. In contrast to the baseline samples, curved samples containing 3% cellulose nanoparticles demonstrated enhanced curved beam strength and interlaminar tensile strength by 4.95% and 3.82%, respectively. Additionally, filler‐loaded samples exhibited reduced delamination and fracture propagation damage compared with baseline samples. The adhesion between the epoxy matrix and infill was investigated by means of Fourier transform infrared analysis. In addition, live photographic images and fractured micrographs were correlated with mechanical findings in order to assess delamination suppression and damage processes in both the arm and arc directions.

Microstructure, mechanical properties and interaction mechanism of seawater sea-sand engineered cementitious composite (SS-ECC) with Glass Fiber Reinforced Polymer (GFRP) bar

With increasing demand for sustainable and long-lasting materials, seawater sea-sand engineered cementitious composite (SS-ECC) has emerged as a promising alternative to conventional concrete in near-ocean construction projects. Glass fiber reinforced polymer (GFRP) bar with excellent corrosion resistance is an ideal choice for these applications. This study evaluated the bond performance of GFRP bars embedded in normal-strength ECC with polyvinyl alcohol (PVA) fibers and high-strength ECC with polyethylene (PE) fibers through pull-out tests. Additionally, tests were conducted on GFRP bars in pristine ECC made with freshwater and river sand for comparison. Further investigation explored the structural properties and uncovered load transfer mechanisms. Results indicated that saline content facilitated early cement hydration of normal-strength ECC, resulting in finer pore structure (10.5% lower porosity and 12.5% lower sorptivity), slightly enhanced compressive performance (1.2% higher compressive strength and 8.3% higher elastic modulus), denser microstructure at GFRP-ECC interface (13.7% lower porous transition zone thickness, 19.2% narrower transition zone and 19.7% higher Ca/Si ratio), and superior bond performance (28.3% higher bond strength and 22.6% higher fracture energy). Conversely, saline content imposed a limited impact on the mechanical properties of high-strength ECC, primarily attributed to the ultra-fine microstructure and early strength characteristics exhibited by the silica fume (SF)-based cementitious binder.

Durability and mechanical characteristics of unidirectional jute/banana and synthetic fiber reinforcement epoxy composite

Corrosive environments affect the physical and mechanical properties of natural fiber-reinforced epoxy composites. In such a context, this study focuses on the durability and corrosive impact on the mechanical properties of bast fiber-based composites. Synthetic glass fiber, and aluminium foil were also used for hybridization. The composites and hybrids were made using unidirectional jute and banana-fiber mats. Composites were immersed in a NaCl solution to create a corrosive environment, and their mechanical properties were investigated. Hybridization with glass fiber has the lowest impact on corrosive conditions. However, in a saline environment, it substantially alters the mechanical properties of composite materials. XRD and SEM were also performed for dry samples, and samples immersed in pH 8. XRD analysis revealed that adding synthetic fiber to natural fiber decreases the crystallinity. Hence, this study shows that hybridizing bast fiber with glass fiber is a noble approach to use in corrosive environments. The experimental results were verified by finite element analysis using ABAQUS.

Experimental and numerical investigation of an additively manufactured sandwich composite bridge deck utilizing gyroid building blocks

This work investigates the integration of Additive Manufacturing (AM) techniques with cellular metamaterials integrated into composite sandwich beam systems. The study proposes an approach that combines composite materials for the face sheets with cellular structures using a Triply Periodic Minimal Surface (TPMS) Gyroid structure for the core to achieve maximum lightweight and load-bearing capabilities. The experimental and numerical campaigns were utilized for the material testing of 3D printing polymeric material reinforced with chopped carbon fibre (CF). To validate the composite sandwich structure, three bending experiments were conducted: (a) bending of the “core only” was performed to calibrate the material for the given print parameters; (b) bending of the “sandwich beam” composite with a periodic and homogenous Gyroid core bonded with glass fibre reinforced polymer (GFRP) face sheets; (c) the “arch beam” composite with the change in outer cross-section dimension with the same periodic and homogenous Gyroid core. The FEM analysis was combined with Digital Image Correlation (DIC) results to determine the bending stiffness of the sandwich beams and to detect the failure modes. It was discovered that integrating 3D printing into load-bearing structures through the composite “sandwich beam” system resulted in seven times increase in load-bearing capacity and four times increase in stiffness compared to results obtained with the “core only” structure.