Hybrid Yarns Research Articles

A two‐scale numerical analysis of intra‐yarn hybrid natural/synthetic woven composites

AbstractThis paper investigates how combining natural and synthetic fibers within yarns, altering the degree of hybridisation, and varying weave architectures affect the homogenized elastic properties and stress distributions in 2D woven composite laminae using a two‐scale homogenization scheme. The novelty lies in integrating a micro‐scale representative volume element model with a meso‐scale repeating unit cell model to capture intra‐yarn natural/synthetic fiber hybridisation. The study focuses on 2/2 twill and 5‐harness satin woven laminae with flax/E‐glass, hemp/E‐glass and basalt/E‐glass hybrid yarns, all with a total fiber volume fraction of 0.6. Fiber distributions are created through a random sequential expansion algorithm for hybrid RVEs, while periodic meso‐structures are used to define weave architectures for RUCs. Results show that yarn‐level fiber hybridisation significantly influences matrix stress distributions, with variations of up to 22%. In contrast, weave architecture has a minimal effect, with variations in homogenized properties below 2%. Varying fiber types, degrees of hybridisation and weave architectures allow for the tailoring of yarn and lamina properties and altering the stress distributions at micro‐ and meso‐scales and potentially influencing damage mechanisms. The modeling approach for analyzing the mechanical behavior of intra‐yarn hybrid natural/synthetic woven laminae could potentially be used to tailor their tolerance to damage.Highlights Two‐scale homogenization integrates RVE and RUC for 2D woven hybrid composites. Analyzed flax/E‐glass, hemp/E‐glass, basalt/E‐glass in twill and satin weaves. Intra‐yarn hybridisation significantly affects properties and stress fields. Hybridizing fibers offers tailored properties and may improve damage tolerance.

Innovative Techniques for Developing Hybrid Yarns Using Different Core Insertion Methods: A Comparative Study

Elastane fibers, in particular, have gained an important share in the production of elastic yarn. This research aims to evaluate innovative methods for developing hybrid yarns (dual core) by integrating core elements in various configurations to show the influence of different core-inserting techniques on yarn characteristics. The research developed a modified pulley (W-grooved roller) to insert core elements side by side along with the existing method during the yarn manufacturing process. Ne 16/1 yarn (dual core) was manufactured using five different core inserting techniques with cotton roving, polybutylene terephthalate (PBT), and elastane (Lycra®). The characteristics of the produced yarns were analyzed using standard testing methods. Statistical analysis was performed to determine significant variations in yarn properties using one-way MANOVA and the MOORA method was employed to determine the most suitable yarn configuration. The results indicate that yarn manufactured by inserting core components side by side significantly enhances the expected characteristics of hybrid yarns. Yarns manufactured by inserting core components side by side show higher strength, elongation, and lower hairiness values. This research introduces a novel technique for producing dual-core yarns by side-by-side insertion of core elements contributing to the development of innovative hybrid yarns.

Comparison of mechanical and flammability properties of thermoplastic and thermoset matrix glass fibre woven fabric composites

This study aims to examine the mechanical and burning properties of composites made from twill (0°/0° and 0°/90° orientations) and plain fabrics using hybrid yarns produced by combining glass and polypropylene yarns with interwoven and intermingled methods. The properties of interwoven and intermingled hybrid fabric composites were compared with thermoset composites. Each composite (56% glass fibre content) plate is produced by combining eight fabrics with the same parameters using the press moulding technique. The effects of yarn and fabric weaving types on the results were examined in detail. When the results are examined, the breakage of glass fibres in intermingled hybrid yarns negatively affects the strength results. Therefore, composites made with intermingled hybrid yarn types and plain weave types of fabric had the lowest tensile strength value (132 MPa). The composite of twill woven fabrics produced with interwoven yarns arranged in 0°/0° orientation had the highest tensile strength of 315 MPa, and these results were very close to those of thermoset composites. Although the 0°/90° oriented twill composite showed a 2.3 times lower tensile strength value than the 0°/0° oriented twill composite, it had a 7.7 times higher value when bending strength values were taken into account. The main reason for this is that glass fibres contribute to the warp and weft directions. It has been observed that the composite consisting of plain fabrics woven with commingled hybrid yarns had the highest impact resistance. Additionally, when the combustion results were examined, it was concluded that the type of yarn and fabric weaving affected the burning rate. The slower combustion of hybrid commingled yarn composites resulted from fibreglass breakage during yarn production. These findings provide valuable insights into optimizing composite materials for specific applications, considering factors such as weaving pattern, fibre orientation, and mechanical performance.

Hybrid yarn structures as a promising approach for thermoplastic biocomposites

The field of composite materials is rapidly expanding due to advancements in materials and manufacturing, driven by environmental concerns for reduced weight, increased energy efficiency, and recyclability. While thermoset composites are crucial, thermoplastics are gaining popularity for their sustainability and manufacturing advantages. They offer quicker processing, easier production, and recyclability, aligning with sustainability goals. While carbon, glass, and aramid fibers remain dominant, natural fibers like flax and hemp offer high performance and affordability with lower environmental impact. Natural-based yarns are finding applications in automotive, construction, consumer goods, and sports equipment. Hybrid yarns, blending natural and polymeric fibers, promote ecological solutions. This review outlines the benefits of natural-based hybrid yarns in thermoplastic composites, exploring production methods and current developments in the field.

Flexible and air-stable n-type oleylamine/carbon nanotube hybrid yarns for high-performance wearable thermoelectric generators

Wearable thermoelectric generators (TEGs), envisioned to harness the temperature gradient (ΔT) between the human body and the environment into electricity, hold great promise for powering wearable electronics. However, their practical application has been hampered by the scarcity of flexible n-type thermoelectric (TE) materials boasting both high performance and long-term air stability. Here, we introduce a significant advancement by developing an n-type TE material through immersing carbon nanotube yarn (CNTY) into an oleylamine (OAm)/ethanol solution, followed by drying under atmospheric conditions. The resulting OAm/CNTY exhibits a Seebeck coefficient of -80.48 μV K-1, an electrical conductivity of 1353.18 S cm-1 and a power factor of 876.25 μW m-1 K-2, all while exhibiting exceptional mechanical flexibility. Notably, this hybrid yarn maintains stable n-type behavior even after enduring exposure to air for over 370 days, surpassing previous n-type TE materials based on CNT fibers and CNTY. Leveraging this advancement, we construct a prototype wearable TEG by alternately embroidering pristine p-type CNTY and n-type OAm/CNTY into a polyester spacer fabric, electrically connecting them in series using conductive silver paint. The resulting wearable TEG, featuring with 150 p-n couples, yields an output voltage of 705.94 mV and a maximum output power of 44.34 μW at a ΔT of 40 K. This groundbreaking work opens new avenues for the development of high-performance, air-stable, and flexible n-type TE material, ushering in a new era for wearable TEGs.

Continuous fabrication of triboelectric/piezoelectric hybrid yarns with high output for self-powered wearable sensors

Yarn-based nanogenerators exhibit potential for use in self-powered wearable sensors. However, their current limitations include intricate manufacturing procedures, low electrical output performance, and a restricted level of reliability. Here, we present a continuous fabrication approach for fabricating triboelectric/piezoelectric hybrid nanogenerators utilizing yarns with integrated exceptional performance. The continuous production process exhibits the attributes of one-step forming, wherein piezoelectric nanofibers and triboelectric silicone rubber covering are simultaneously and effectively attached to a single yarn to create yarn-based hybrid nanogenerators. The hybrid yarn demonstrates exceptional electrical output performance by harnessing the advantages of both piezoelectric and triboelectric effects, resulting in a power density of 26.72 μW/m2 at 17 MΩ. Demonstrating high sensitivity, stability, and mechanical resilience, yarn-based hybrid nanogenerators are suitable for self-powered wearable sensors, enabling applications in Morse code recognition and gait detection. This innovation in yarn-based nanogenerators broadens their scope, heralding new possibilities in the energy-harvesting device and wearable technology.

IMAGE-BASED CROSS-SECTIONAL ANALYSIS AND MICROMECHANICAL MODELING OF YARN AND COMPOSITE MATERIALS

This study aims to establish a comprehensive methodology for determining the microstructural properties of hybrid yarns used in composite materials. By developing accurate models of hybrid yarns and composites based on detailed microstructural information such as fibre orientation, fibre diameter and distribution, this approach lays the foundation for future advances. These models, enriched with accurate microstructural data, will facilitate the creation of new modelling techniques that can be used in future research to explore the correlation between microstructural properties and mechanical performance of composite materials.

Effect of Self‐Incandescent Heating on Superconducting NbN Nanowire Yarn

AbstractA flexible superconducting yarn composed of twisted niobium nitride (NbN) nanofibrils is developed and exhibited a superconducting transition temperature that met the reported record of ≈17 K. NbN is sputter‐deposited onto a template of aligned single‐layer carbon nanotube (CNT) sheets and subsequently processed by post‐Joule heat annealing following the insertion of twists. Considering self‐Joule heating approaches the level of incandescent light emission, the melting, reflow, and recrystallization of the NbN layer around each CNT template occurred, considerably enhancing the macroscopic superconducting properties of the NbN nanofibrillar yarn, including the critical current density and critical magnetic field. Furthermore, the superconducting performance, which degrades as a result of mechanical damage to the internal structure under excessive stress such as bending, can be restored by the reflow of the NbN during this process. Considering the melting point of NbN is higher than 2800 K, the proposed incandescent light‐emission‐driven Joule self‐heating process is considered an effective method for improving the properties of CNT‐templated metal hybrid yarns.

Biscrolled hierarchical hybrid structure of PEDOT:PSS/CNTs-NMP yarn based solid state linear supercapacitor for wearable e-textile

The environmental friendly flexible solid state linear supercapacitor (FSLSc) based on the hierarchical hybrid yarn with core-shell type structure of poly(3,4-ethylenedioxythiophene): polystyrenesulfonate (PEDOT:PSS) and hydrophilic carbon nanotubes (CNTs) sheet, fabricated using novel biscrolling technique is proposed. The hierarchical hybrid yarn structure of the electrode establishes the improved electrochemical interface of PEDOT:PSS with the both the hydrophilic CNTs and an aqueous PVA/H3PO4 gel electrolyte. The exterior surface of the yarn electrode rich in PEDOT:PSS which interact with ions from electrolyte and stores charges faradaically while the core region with dense CNTs yarn contributes with its multifunctional capabilities such as EDLC type capacitor, current collector and mechanical support. The observed two-fold decrease in ESR value (∼49Ω) and two-fold increase in capacitance (∼112.76 F/g) for hybrid yarn electrode with N-methyl-2-pyrrolidone (NMP) treated hydrophilic CNTs compared to the one with pristine CNTs, confirms the improved interface of PEDOT:PSS formed with hydrophilic CNTs and aqueous electrolyte. The FSLSc devices with NMP treated CNTs hybrid yarn electrodes exhibited excellent electrochemical performance in terms of the maximum power and energy density of 980 W/kg and 3.799 Wh/kg, respectively. The FSLSc displayed remarkable cycling performance upto 5000 cycles of charge-discharge and a robust bending stability after 1000 bending cycles, making it promising for practical application of the next-generation flexible solid state electrochemical energy storage in e-textiles.

Three‐dimensional (3D) woven flax fiber/polylactic acid (PLA) composites for high flexural strength

AbstractThree dimensional (3D) textiles are preferable reinforcing materials for composites with lightweight and higher mechanical properties. In this study, a 3D woven flax fiber reinforced PLA composite with better flexural and tensile properties was developed. Four hybrid yarns with varied PLA contents were prepared as warp, weft and z‐yarns to weave the 3D preform and then changed to composites through compression molding technology without additional fillers and matrixes. The composite's flexural and tensile properties were studied and an optimum value of 78.0 and 140.0 MPa respectively were found. Stress strain properties were also discussed which implies the flexural elongation is higher than those of tensile values. The microstructure was analyzed using optical microscope and SEM equipment's showed composites with higher PLA content were more brittle due to the PLA inimitable behavior. The thermal properties of the 3D composites made with different Flax/PLA combinations have closer and comparable values. One way ANOVA statistical analysis was done to show the significancy of PLA /Flax mass ratio, which has a significant effect on composite's properties. This study could bring a novel procedural approach for an advanced 3D woven composites for load bearing applications.Highlights 3D woven flax /PLA composite was developed using Flax/PLA hybrid yarns Tensile and flexural properties were studied Flexural strength increases with PLA, but, slightly lower in its strain PLA/Flax mass ratio has a significant effect on composite's properties The mechanical strengths were improved compared to the related findings

Revitalizing high-density polyethylene (HDPE) waste: from environmental collection to high-strength hybrid yarns

Plastic products are used in large quantities. However, the fact that plastics do not degrade in nature for many years causes environmental pollution. Addressing this issue, the study focuses on recycling the widespread high-density polyethylene (HDPE) plastic waste. In this study, HDPE waste was collected randomly from the environment, mirroring real-world scenarios. Then, the waste was transformed into granules. Afterward, washing and drying processes were carried out. HDPE filaments of different linear densities were successfully produced from the waste plastic granules. Tensile tests revealed that the breaking strength of the filaments from waste plastic was lower than that of virgin HDPE filaments, highlighting the challenges of recycling. Hybrid yarns were formed by twisting the filaments with cotton yarn to improve the mechanical properties of the filaments from waste plastic. Remarkably, statistical analysis demonstrated that the breaking load values of the hybrid yarns from waste plastic were statistically equivalent to those made from virgin polymer. This outcome indicated that the hybrid yarns made from waste HDPE plastic were as strong as those made from virgin HDPE polymer. In addition, both hybrid yarns exhibited a breaking load 36% higher than the reference extra-twisted cotton yarn. The hybrid yarn formation made filaments produced from waste plastic a valuable component of the high-strength hybrid yarn. Overall, this study shows that recycling HDPE plastics can lead to the production of high-strength hybrid yarns, which can contribute to reducing plastic waste pollution.

Impact of hot air gun soldering process parameters on the electromechanical properties of electronic yarn

Researchers now confirm that the market for electronic textiles, or ‘E-textiles,’ will rise rapidly. One method of creating e-textiles is the integration of electronics with textiles. Several techniques were used to combine electronics with conductive textile. One of the best methods for connecting electronics to conductive textile fabrics is soldering. Because of this, it is important to look into how the soldering process parameter affects the developed e-textile’s characteristics. In the research paper presented, the effects of temperature, speed of hot air, and amount of paste size of hot air gun re-flow soldering parameters on the electromechanical properties of surface mount device (SMD) embedded electronic yarn were examined. Three main soldering parameters at four different levels were selected based on the preliminary test results involving the soldering of the tiny SMD into CLEVERTEX electrically conductive hybrid yarn. The result shows that soldering of SMD into CLEVERTEX electrically conductive hybrid yarn provided a higher conductivity with 10-ohm DC resistance. Statistical analyses were also carried out to prove the significant effect of the temperature on changing electrical resistance at, α = 0.5, with an F-value of 0.27 and a p value of .036. While the effects of different amounts of solder paste size on the electrical resistance were not statistically significant at α = 0.5, with an F-value of 0.27 and a p value of .84. Moreover, the tensile strength of the developed e-yarn was affected by the hot air soldering parameters. Furthermore, the developments of e-yarn using hot air gun soldering was pronounced in more extreme process conditions, which revealed that there was a strong interaction between the solder temperature, solder paste volume and solder speed. Furthermore, this approach made it easier to generate the optimum quality of e-yarn needed to continue creating prototype electronic textiles.

Tensile and impact properties of thermoplastic fibre hybrid composites based on air textured commingling hybrid yarns composed of carbon/aramid/polyamide 6 and carbon/glass/polyamide 6 filament yarns

This paper reports a comparison of tensile and impact properties between carbon/aramid and carbon/glass fibres reinforced unidirectional thermoplastic hybrid composites. For this purpose, different hybrid composites were produced using commingled hybrid yarns of carbon/aramid/polyamide 6 filament yarns and carbon/glass/polyamide 6 filament yarns with a defined mixing ratio based on air texturing technology. The results show that the density and specific Youngs’ modulus of the composites changes linearly with the proportion of carbon/glass and carbon/aramid fibre in hybrid composites. The specific Young’s modulus decreases linearly with decreasing carbon fibre content in the hybrid composites. On the other hand, the specific tensile strength does not change linearly according to the rule of mixture and a negative hybridization effect can be observerd for both types of hybrid composites. Furthermore, the combination of carbon/aramid and carbon/glass fibres can increase the impact strength by approximately 204% and 218%, respectively, compared to the composite reinforced by CF only. Although the specific tensile strength and specific impact strength of carbon/aramid reinforced hybrid composites are higher than those of CF/GF hybrid composites due to the lower density of carbon/glass hybrid composites, the potential impact strength achievable in hybrid composites is higher with the carbon/glass combination than with the carbon/aramid combination.

Effects of structural parameters on radial crashworthiness of 3D braided hybrid tubes with Janus structure

Hybrid fiber reinforced plastic (HFRP) composites have been widely used in various fields, but delamination is a fatal damage mode in laminated hybrid tubes. In the current paper, carbon fibers/Kevlar fibers hybrid tubes with Janus structure were fabricated by three-dimensional (3D) tubular braiding technique. The radial crushing performances of 3D braided Janus hybrid tubes were analyzed while hybrid layer ratio and yarn type were both considered. With the increase of hybrid layer ratio from 1:3 to 2:2 to 3:1, the specific energy absorption (SEA) increased 149 % and 21.39 % for specimens with carbon fibers placed on the skin region, and that decreased 12.46 % and 10.66 % for samples with Kevlar fibers arranged on the skin region. Furthermore, samples with Kevlar fibers arranged on the skin region presented excellent radial crashworthiness. The current work could be helpful for the design, fabrication and application of HFRP tubes.

Twisted integration of high-efficiency photothermal/water-transported yarns for boosting solar-powered fabric evaporator

Positioned as high-efficiency low-cost desalination technology, solar interfacial vapor generation still remains challenging in precisely managing interfacial photothermal behaviors. Here, an integral solar-heating yarn twisted by both carbon nanotube (CNT) fibers and cotton yarns processed via carbon black slurry is developed for architecting high-efficiency fabric evaporators, where modified CNT and cotton serve as the solar-heating unit and water-supply unit, respectively. The unique structure of hybrid yarns features pronounced gradient photothermal difference of 5 °C between CNT and cotton regions in dry state, and meanwhile enables robust Marangoni vapor flows and weak hydration state. As a result, the crafted fabric evaporator has a superior evaporation rate of 2.83 kg m−2 h−1, which is the highest value reported among 2D fabric evaporators. This work introduces an innovative strategy for high-efficiency interfacial solar heating, significantly boosting evaporation performance of flexible and portable evaporators.

Investigations on the development of impact-resistant thermoplastic fibre hybrid composites from glass and steel fibre

With the increased use of fibre reinforced composites (FRP), the design of new generation of composite structures with high stiffness and a ductile material behaviour is required to cope with complex load scenarios and high damage tolerances. This can be achieved, in particular, by a combination of conventional fibre-reinforced composites (FRP), which possess high stiffness and strength with metallic materials characterized by their high ductility and associated higher energy absorption capacity. Currently, there are no solutions for hybridisation of high performance filament yarns, metal filament yarns and thermoplastic filament yarns on micro level. Therefore, the main objective of this study is to develop a fibre hybrid composite based on hybrid yarn consisting of glass, steel and polypropylene filament yarns and to compare its tensile and impact properties with those of the composite reinforced only with glass filament yarn. The tensile and impact properties of the unidirectional hybrid composites produced from the developed multi-material hybrid yarn consisting of steel, glass and polypropylene filament yarns are compared with those of a non-hybrid composite reinforced exclusively with glass filament yarn. The results show that by hybridising with steel fibres a characteristic post-failure behaviour can be achieved, so that the developed multi-material hybrid yarns have a high potential for use in composites with high crash and impact performance requirements, where safety demands are essential.

A Comparative Study of the Experimental Investigation of different types of fibres used in Concrete

Different types of fibres used in concrete have received much attention in civil engineering in recent years, mainly because they improve the low tensile strength and shrinkage cracks of concrete. However, there are still many problems in the research results on different types of Fibers. For example, there is still debate about the performance-enhancing or detrimental effects of different types of fibres in concrete. There is also a dispute about the influence of the size, strength, elastic modulus and other characteristic parameters of each fibre on the properties of the substrate. Research on fibre mixing rules of hybrid fibre reinforced concrete (HFRC) is incomplete. There is controversy regarding the choice of fibres for hybrid yarns as well as the characterization of the hybrid effect. In summary, it is necessary to review, synthesize and compare current research on FRC. Based on the major research achievements on FRC in recent years, this article synthesizes and evaluates existing research in experimental research and theoretical research on different types of fibre materials, aiming to create Reference conditions for researchers in the same field. Finally, combined with research experience in related fields, new perspectives and proposals on FRC's research are proposed for research and application. This research paper is mainly focus on the different fibres (glass, cotton, steel). KEYWORDS:- GLASS FIBRE, COTTON FIBRE, STEEL FIBRE, TENSILE STRENGTH, COMPRESSIVE STRENGTH,

Neural Network Based Determination of the Degree of Fiber Mixing in Hybrid Yarns and Composites

A deep understanding on the intermixing of components in hybrid yarn or composite structures is decisive in order to develop hybrid structures with desired properties. This paper presents the development of a versatile procedure for the determination of the degree of fiber mixing in yarns and composites based on microscopy images auto-segmented by a neural network. The procedure is based on the quantification of blend irregularity values and blend homogeneity. For this purpose, functions of spatial point patterns analysis have been used to investigate the blend uniformity of yarn and composite cross sectional areas. The results show that the trained neural network model for segmentation of images has an accuracy of 92 %, indicating that the method is capable of accurately assessing the location of fibers in hybrid struc-tures. The results of the spatial point patterns analysis reveals a correlation between the blend value and the properties of yarns and composites. The proposed method provides a fast and reliable way to evaluate the hybrid structures, which could be used as a tool for quality control and process optimization.

Continuous additive manufacturing of hemp yarn-reinforced biocomposites with improved impregnation method

This study was motivated by the development of new additively manufactured bio-based materials with high performance. Hemp yarn was used in continuous material extrusion additive manufacturing to produce novel hemp yarn-reinforced biocomposites. The hemp yarn was compared to an original hemp/poly(lactic acid) hybrid yarn prepared by commingling before printing as an improved impregnation method. In X-ray micro-computed tomography, the hybrid yarn-based biocomposite exhibited a higher impregnation rate accompanied by a reduced void content, more aligned fibers, and a more homogeneous distribution of the different constituents, resulting in significantly higher mechanical properties during tensile loading with a more brittle behavior compared to the additively manufactured biocomposite based on pure hemp yarn. In addition, superior mechanical performance was obtained while having lower fiber fraction with the use of hybrid yarns, raising awareness about the importance of improving the impregnation of the plant fibers as well as the fiber volume fraction. This original preparation method can provide bio-based materials with enhanced quality and performance, close to those obtained with conventional manufacturing techniques, while making the most of additive manufacturing for sustainable, lightweight, and high-end applications in health or aerospace.

Micromechanical Modelling of the Deformation Mechanisms of Friction-Spun Yarn from Recycled Carbon Fibres

The growing use of carbon fibre-reinforced polymers (CFRP) results in an increased amount of CF waste from offcuts or end-of-life components. A promising method to reuse the waste fibre materials in a structural component with excellent mechanical properties is the processing of recycled CF (rCF) and thermoplastic fibres into hybrid yarns. Spinning of friction spun yarns consisting of more than 90% rCF and containing almost no thermoplastic fibres that are suitable for thermoset composites, currently leads to high fibre damage and low yarn quality and is, therefore, addressed in this project. The technology is reported in another paper. One of the limiting factors for drapability of textiles is the stretchability of continuous fibres and draping of the semi-finished textile products for complex geometries is still error-prone. Friction spun yarns exhibit significantly higher yarn elongations due to sliding mechanisms between the fibres. The deformation properties of friction spun yarns are significantly influenced by fibre-fibre interactions and depend on a variety of process and material parameters. In the following, micromechanical finite element models of the spun yarns are created by using beam elements. Monte Carlo method is used to model local variabilities in the yarns. The models are then used to simulate yarn behaviour under deformation and to investigate the influence of various process parameters.